U.S. patent application number 15/973297 was filed with the patent office on 2018-10-04 for methods and systems for data storage and communication in an internet of things chemical production process.
The applicant listed for this patent is StrongForce IoT Portfolio 2016, LLC. Invention is credited to Charles Howard Cella, Mehul Desai, Gerald William Duffy, JR., Jeffrey P. McGuckin.
Application Number | 20180284753 15/973297 |
Document ID | / |
Family ID | 63669288 |
Filed Date | 2018-10-04 |
United States Patent
Application |
20180284753 |
Kind Code |
A1 |
Cella; Charles Howard ; et
al. |
October 4, 2018 |
METHODS AND SYSTEMS FOR DATA STORAGE AND COMMUNICATION IN AN
INTERNET OF THINGS CHEMICAL PRODUCTION PROCESS
Abstract
A system, method and apparatus for data collection related to a
chemical production process are described. The system may include a
cross point switch including a plurality of inputs and a plurality
of outputs, a plurality of sensors operatively coupled to at least
one of a plurality of components of the chemical production
process, a sensor data storage profile circuit structured to
determine a data storage profile, wherein the cross point switch is
responsive to the data storage profile to selectively couple at
least one of the plurality of inputs to at least one of the
plurality of outputs, a sensor communication circuit
communicatively coupled to the plurality of outputs of the cross
point switch, and a sensor data storage implementation circuit
structured to store at least a portion of the plurality of sensor
data values in response to the data storage profile.
Inventors: |
Cella; Charles Howard;
(Pembroke, MA) ; Duffy, JR.; Gerald William;
(Philadelphia, PA) ; McGuckin; Jeffrey P.;
(Philadelphia, PA) ; Desai; Mehul; (Oak Brook,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
StrongForce IoT Portfolio 2016, LLC |
Santa Monica |
CA |
US |
|
|
Family ID: |
63669288 |
Appl. No.: |
15/973297 |
Filed: |
May 7, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2017/031721 |
May 9, 2017 |
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15973297 |
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62333589 |
May 9, 2016 |
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62350672 |
Jun 15, 2016 |
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62412843 |
Oct 26, 2016 |
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62427141 |
Nov 28, 2016 |
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62540557 |
Aug 2, 2017 |
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62562487 |
Sep 24, 2017 |
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62583487 |
Nov 8, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06N 20/00 20190101;
G06K 9/6263 20130101; G05B 23/0294 20130101; G06Q 30/02 20130101;
G05B 2219/45004 20130101; G06N 3/0445 20130101; H04B 17/40
20150115; G05B 19/4185 20130101; G05B 23/0286 20130101; G05B
23/0291 20130101; G05B 19/41875 20130101; G05B 2219/37337 20130101;
G06N 3/02 20130101; H04L 67/306 20130101; H04L 67/12 20130101; G05B
2219/32287 20130101; G06N 3/0454 20130101; G05B 19/4183 20130101;
H04L 67/1097 20130101; Y02P 90/02 20151101; H04B 17/23 20150115;
G05B 23/0264 20130101; G06N 3/0472 20130101; G05B 2219/35001
20130101; H04W 4/70 20180201; G05B 23/0229 20130101; G05B
2219/37351 20130101; G06N 3/006 20130101; G06Q 30/06 20130101; G06N
7/005 20130101; G05B 19/042 20130101; G05B 2219/37434 20130101;
H04B 17/29 20150115; H04L 1/1874 20130101; G05B 23/0297 20130101;
G05B 2219/45129 20130101; H04B 17/26 20150115; G05B 23/024
20130101; G06N 5/046 20130101; H04L 1/0041 20130101; G05B 23/0283
20130101; H04B 17/318 20150115; H04L 1/0002 20130101; H04L 1/0009
20130101; H04W 4/38 20180201; G05B 23/0289 20130101; G05B 19/41845
20130101; G05B 19/4184 20130101; G05B 23/0221 20130101; H04L 1/18
20130101; G05B 2219/40115 20130101; G06N 3/084 20130101; G06N 3/088
20130101; G06N 3/126 20130101; H04B 17/345 20150115; H04B 17/309
20150115; H04L 5/0064 20130101; Y02P 90/80 20151101; G05B 13/028
20130101; G05B 19/41865 20130101; Y02P 80/10 20151101 |
International
Class: |
G05B 23/02 20060101
G05B023/02; G05B 19/418 20060101 G05B019/418; H04L 29/08 20060101
H04L029/08 |
Claims
1. A system for data collection related to a chemical production
process, the system comprising: an analog switch comprising a
plurality of inputs and a plurality of outputs; a plurality of
sensors operatively coupled to at least one of a plurality of
components of the chemical production process, and each
communicatively coupled to at least one of the plurality of inputs
of the analog switch; a sensor data storage profile circuit
structured to determine a data storage profile, the data storage
profile comprising a data storage plan for the plurality of sensor
data values; wherein the analog switch is responsive to the data
storage profile to selectively couple at least one of the plurality
of inputs to at least one of the plurality of outputs; a sensor
communication circuit communicatively coupled to the plurality of
outputs of the analog switch, and structured to interpret a
plurality of sensor data values; and a sensor data storage
implementation circuit structured to store at least a portion of
the plurality of sensor data values in response to the data storage
profile.
2. The system of claim 1, wherein the data storage profile further
comprises at least one of: a storage location for the at least one
of the plurality of sensor data values; a time data storage
trajectory comprising a plurality of time values corresponding to a
plurality of storage locations over which the corresponding at
least one of the plurality of sensor data values is to be stored; a
time domain distribution over which the at least one of the
plurality of sensor data values is to be stored; and location data
storage trajectory comprising a plurality of storage locations over
which the at least one of the plurality of sensor data values is to
be stored.
3. The system of claim 1, wherein the sensor data storage
implementation circuit is further structured to store at least one
of calibration data and maintenance history for at least one of the
plurality of input sensors, and wherein the sensor communication
circuit is further configured to perform one of calibrating the at
least one of the plurality of input sensors and updating the
maintenance history of the at least one of the plurality of input
sensors.
4. The system of claim 1, wherein the sensor communication circuit
comprises a plurality of distributed processing circuits.
5. The system of claim 1, wherein the chemical production process
comprises a pharmaceutical production process.
6. The system of claim 1, wherein the data storage profile further
comprises a data communication path, and wherein the plurality of
sensor data values is communicated through a network infrastructure
along the data communication path.
7. The system of claim 6, wherein the data storage profile further
comprises a plurality of data communication paths, and wherein a
selected one of the plurality of data communication paths is
determined in response to at least one hierarchical template.
8. The system of claim 7, further comprising the sensor data
storage profile circuit further structured to select a hierarchical
template in response to at least one condition selected from the
conditions consisting of: a component type associated with one of
the plurality components; a process stage of the chemical
production process; an operational mode for at least one of the
chemical production process, one of the plurality of sensors, or
one of the components; an operating condition of one of the
plurality of components; a diagnostic operation for one of the
plurality of components; a diagnostic operation for the chemical
production process; an offset process from the chemical production
process; a network availability for at least a portion of the
network infrastructure; a sensor availability for at least one of
the plurality of sensors; and an environmental condition associated
with the chemical production process.
9. The system of claim 8, wherein the sensor data storage profile
circuit further comprises at least one of a rule-based expert
system or a model-based expert system.
10. The system of claim 1, wherein the at least one of the
plurality of components of the chemical production process
comprises at least one component selected from the components
consisting of: a mechanical agitator, a rotating agitator, a
propeller agitator, a pump, a mixing tank, a heating vessel, a
variable speed motor, a fan, bearings and associated shafts,
motors, rotors, stators, or gears.
11. A computer-implemented method for monitoring data collection in
a chemical production facility, the method comprising: interpret a
plurality of sensor data values from a plurality of sensors each
operatively coupled to at least one of a plurality of components of
a chemical production process; determine a data storage profile,
the data storage profile comprising a data storage plan for the
plurality of sensor data values; selectively couple at least one of
a plurality of inputs of an analog switch to at least one of a
plurality of outputs of the analog switch in response to the data
storage profile, wherein the each of the plurality of sensors are
communicatively coupled to at least one of the plurality of inputs
of the analog switch; interrogate at least a portion of the
plurality of sensor data values from the plurality of outputs of
the analog switch; and store at least a portion of the interrogated
sensor data values in response to the data storage profile.
12. The method of claim 11, further comprising selectively
communicating and storing the at least a portion of the
interrogated sensor data values in a plurality of storage locations
in response to the data storage profile.
13. The method of claim 12, wherein the selectively communicating
and storing the at least a portion of the interrogated sensor data
values comprises performing at least one operation selected from
the operations consisting of: sequentially moving at least a
portion of the interrogated sensor data values between storage
locations; storing selected portions of the at least a portion of
the interrogated sensor data values in selected storage locations
for selected time periods; providing a time data storage trajectory
for at least a portion of the interrogated sensor data values;
providing a time domain distribution over which at least a portion
of the interrogated sensor data values are to be stored; and
providing a location data storage trajectory over which at least a
portion of the interrogated sensor data values are to be
stored.
14. The method of claim 9, further comprising storing at least one
of calibration data and maintenance history for at least one of the
plurality of input sensors, and performing one of calibrating at
least one of the plurality of input sensors and updating the
maintenance history of one of the plurality of input sensors.
15. The method of claim 9, further comprising adjusting the data
storage profile in response to a network resource value to move a
data storage load between a first networked device and a second
networked device, wherein the first networked device is
communicatively disposed between the second networked device and
the analog switch.
16. The method of claim 15, wherein the adjusting comprises moving
the data storage load toward the first networked device in response
to at least one of: the network resource value indicating a reduced
network capacity; and determining the first networked device
comprises sufficient storage capacity to store a selected amount of
the portion of the interrogated sensor data until an expected
network capacity increase event.
17. The method of claim 15, wherein the adjusting comprises moving
the data storage load toward the second networked device in
response to the network resource value indicating a sufficient
network capacity.
18. A monitoring apparatus for data collection related to a
chemical production process, the apparatus comprising: a sensor
data storage profile component configured to determine a data
storage profile, the data storage profile comprising a data storage
plan for the plurality of sensor values; a sensor communication
component configured to interpret a plurality of sensor values
provided at outputs an analog switch, each of the plurality of
sensor values corresponding to input received from at least one of
a plurality of input sensors, each of the plurality of input
sensors operatively coupled to at least one of a plurality of
components of the chemical production process and communicatively
coupled to at least one input of the analog switch, the inputs and
outputs of the analog switch selectively coupled based on the data
storage profile; and a sensor data storage implementation component
configured to store at least a portion of the plurality of sensor
values in response to the data storage profile.
19. The apparatus of claim 18, wherein at least one of the
plurality of sensor values comprises a sensor fusion value.
20. The apparatus of claim 18, wherein the data storage profile
further comprises a data communication path, and wherein the
plurality of sensor data values is communicated through a network
infrastructure along the data communication path.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a bypass continuation-in-part of
International Application Number PCT/US2017/031721, filed: May 9,
2017, entitled METHODS AND SYSTEM FOR THE INDUSTRIAL INTERNET OF
THINGS, published on Nov. 16, 2017, as WO/2017/196821, and which
claims priority to U.S. Provisional Patent Application Ser. No.
62/333,589, filed May 9, 2016, entitled STRONG FORCE INDUSTRIAL IOT
MATRIX; U.S. Provisional Patent Application Ser. No. 62/350,672,
filed Jun. 15, 2016, entitled STRATEGY FOR HIGH SAMPLING RATE
DIGITAL RECORDING OF MEASUREMENT WAVEFORM DATA AS PART OF AN
AUTOMATED SEQUENTIAL LIST THAT STREAMS LONG-DURATION AND GAP-FREE
WAVEFORM DATA TO STORAGE FOR MORE FLEXIBLE POST-PROCESSING; U.S.
Provisional Patent Application Ser. No. 62/412,843, filed Oct. 26,
2016, entitled METHODS AND SYSTEMS FOR THE INDUSTRIAL INTERNET OF
THINGS; and U.S. Provisional Patent Application Ser. No.
62/427,141, filed Nov. 28, 2016, entitled METHODS AND SYSTEMS FOR
THE INDUSTRIAL INTERNET OF THINGS. This application also claims
priority to U.S. Provisional Patent Application Ser. No.
62/540,557, filed Aug. 2, 2017, entitled SMART HEATING SYSTEMS IN
AN INDUSTRIAL INTERNET OF THINGS; U.S. Provisional Patent
Application Ser. No. 62/562,487, filed Sep. 24, 2017, entitled
METHODS AND SYSTEMS FOR THE INDUSTRIAL INTERNET OF THINGS; and U.S.
Provisional Patent Application Ser. No. 62/583,487, filed Nov. 8,
2017, entitled METHODS AND SYSTEMS FOR THE INDUSTRIAL INTERNET OF
THINGS. The above applications are hereby incorporated by reference
as if fully set forth herein in their entirety.
BACKGROUND
1. Field
[0002] The present disclosure relates to methods and systems for
data collection in industrial environments, as well as methods and
systems for leveraging collected data for monitoring, remote
control, autonomous action, and other activities in industrial
environments.
2. Description of the Related Art
[0003] Heavy industrial environments, such as environments for
large scale manufacturing (such as manufacturing of aircraft,
ships, trucks, automobiles, and large industrial machines), energy
production environments (such as oil and gas plants, renewable
energy environments, and others), energy extraction environments
(such as mining, drilling, and the like), construction environments
(such as for construction of large buildings), and others, involve
highly complex machines, devices and systems and highly complex
workflows, in which operators must account for a host of
parameters, metrics, and the like in order to optimize design,
development, deployment, and operation of different technologies in
order to improve overall results. Historically, data has been
collected in heavy industrial environments by human beings using
dedicated data collectors, often recording batches of specific
sensor data on media, such as tape or a hard drive, for later
analysis. Batches of data have historically been returned to a
central office for analysis, such as undertaking signal processing
or other analysis on the data collected by various sensors, after
which analysis can be used as a basis for diagnosing problems in an
environment and/or suggesting ways to improve operations. This work
has historically taken place on a time scale of weeks or months,
and has been directed to limited data sets.
[0004] The emergence of the Internet of Things (IoT) has made it
possible to connect continuously to, and among, a much wider range
of devices. Most such devices are consumer devices, such as lights,
thermostats, and the like. More complex industrial environments
remain more difficult, as the range of available data is often
limited, and the complexity of dealing with data from multiple
sensors makes it much more difficult to produce "smart" solutions
that are effective for the industrial sector. A need exists for
improved methods and systems for data collection in industrial
environments, as well as for improved methods and systems for using
collected data to provide improved monitoring, control, intelligent
diagnosis of problems and intelligent optimization of operations in
various heavy industrial environments.
[0005] Industrial system in various environments have a number of
challenges to utilizing data from a multiplicity of sensors. Many
industrial systems have a wide range of computing resources and
network capabilities at a location at a given time, for example as
parts of the system are upgraded or replaced on varying time
scales, as mobile equipment enters or leaves a location, and due to
the capital costs and risks of upgrading equipment. Additionally,
many industrial systems are positioned in challenging environments,
where network connectivity can be variable, where a number of noise
sources such as vibrational noise and electro-magnetic (EM) noise
sources can be significant an in varied locations, and with
portions of the system having high pressure, high noise, high
temperature, and corrosive materials. Many industrial processes are
subject to high variability in process operating parameters and
non-linear responses to off-nominal operations. Accordingly,
sensing requirements for industrial processes can vary with time,
operating stages of a process, age and degradation of equipment,
and operating conditions. Previously known industrial processes
suffer from sensing configurations that are conservative, detecting
many parameters that are not needed during most operations of the
industrial system, or that accept risk in the process, and do not
detect parameters that are only occasionally utilized in
characterizing the system. Further, previously known industrial
systems are not flexible to configuring sensed parameters rapidly
and in real-time, and in managing system variance such as
intermittent network availability. Industrial systems often use
similar components across systems such as pumps, mixers, tanks, and
fans. However, previously known industrial systems do not have a
mechanism to leverage data from similar components that may be used
in a different type of process, and/or that may be unavailable due
to competitive concerns. Additionally, previously known industrial
systems do not integrate data from offset systems into the sensor
plan and execution in real time.
SUMMARY
[0006] The present disclosure describes a system for data
collection related to a chemical production process, the system
according to one disclosed non-limiting embodiment of the present
disclosure can include a cross point switch including a plurality
of inputs and a plurality of outputs, a plurality of sensors
operatively coupled to at least one of a plurality of components of
the chemical production process, and each communicatively coupled
to at least one of the plurality of inputs of the cross point
switch, a sensor data storage profile circuit structured to
determine a data storage profile, the data storage profile
including a data storage plan for the plurality of sensor data
values, wherein the cross point switch is responsive to the data
storage profile to selectively couple at least one of the plurality
of inputs to at least one of the plurality of outputs, a sensor
communication circuit communicatively coupled to the plurality of
outputs of the cross point switch, and structured to interpret a
plurality of sensor data values, and a sensor data storage
implementation circuit structured to store at least a portion of
the plurality of sensor data values in response to the data storage
profile.
[0007] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the data
storage profile further includes at least one of a storage location
for the at least one of the plurality of sensor data values, a time
data storage trajectory including a plurality of time values
corresponding to a plurality of storage locations over which the
corresponding at least one of the plurality of sensor data values
is to be stored, a time domain distribution over which the at least
one of the plurality of sensor data values is to be stored, and
location data storage trajectory including a plurality of storage
locations over which the at least one of the plurality of sensor
data values is to be stored.
[0008] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the sensor
data storage implementation circuit is further structured to store
at least one of calibration data and maintenance history for at
least one of the plurality of input sensors, and wherein the sensor
communication circuit is further configured to perform one of
calibrating the at least one of the plurality of input sensors and
updating the maintenance history of the at least one of the
plurality of input sensors.
[0009] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the sensor
communication circuit includes a plurality of distributed
processing circuits.
[0010] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the chemical
production process includes a pharmaceutical production
process.
[0011] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the data
storage profile further includes a data communication path, and
wherein the plurality of sensor data values are communicated
through a network infrastructure along the data communication
path.
[0012] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the data
storage profile further includes a plurality of data communication
paths, and wherein a selected one of the plurality of data
communication paths is determined in response to at least one
hierarchical template.
[0013] A further embodiment of any of the foregoing embodiments of
the present disclosure may further include situations where in the
sensor data storage profile circuit is further structured to select
a hierarchical template in response to at least one condition
selected from the conditions consisting of a component type
associated with one of the plurality components, a process stage of
the chemical production process, an operational mode for at least
one of the chemical production process, one of the plurality of
sensors, or one of the components, an operating condition of one of
the plurality of components, a diagnostic operation for one of the
plurality of components a diagnostic operation for the chemical
production process an offset process from the chemical production
process, a network availability for at least a portion of the
network infrastructure a sensor availability for at least one of
the plurality of sensors and an environmental condition associated
with the chemical production process.
[0014] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the sensor
data storage profile circuit further includes at least one of a
rule-based expert system or a model-based expert system.
[0015] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the at least
one of the plurality of components of the chemical production
process includes at least one component selected from the
components consisting of a mechanical agitator, a rotating
agitator, a propeller agitator, a pump, a mixing tank, a heating
vessel, a variable speed motor, a fan, bearings and associated
shafts, motors, rotors, stators, or gears.
[0016] The present disclosure describes a method for monitoring
data collection in a chemical production facility, the method
according to one disclosed non-limiting embodiment of the present
disclosure can include interpreting a plurality of sensor data
values from a plurality of sensors each operatively coupled to at
least one of a plurality of components of a chemical production
process, determining a data storage profile, the data storage
profile including a data storage plan for the plurality of sensor
data values, selectively coupling at least one of a plurality of
inputs of a cross point switch to at least one of a plurality of
outputs of the cross point switch in response to the data storage
profile, wherein the each of the plurality of sensors are
communicatively coupled to at least one of the plurality of inputs
of the cross point switch, interrogating at least a portion of the
plurality of sensor data values from the plurality of outputs of
the cross point switch, and storing at least a portion of the
interrogated sensor data values in response to the data storage
profile.
[0017] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes selectively communicating and storing the at least
a portion of the interrogated sensor data values in a plurality of
storage locations in response to the data storage profile.
[0018] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein selectively
communicating and storing the at least a portion of the
interrogated sensor data values includes performing at least one
operation selected from the operations consisting of sequentially
moving at least a portion of the interrogated sensor data values
between storage locations, storing selected portions of the at
least a portion of the interrogated sensor data values in selected
storage locations for selected time periods, providing a time data
storage trajectory for at least a portion of the interrogated
sensor data values, providing a time domain distribution over which
at least a portion of the interrogated sensor data values are to be
stored and providing a location data storage trajectory over which
at least a portion of the interrogated sensor data values are to be
stored.
[0019] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes storing at least one of calibration data and
maintenance history for at least one of the plurality of input
sensors, and performing one of calibrating at least one of the
plurality of input sensors and updating the maintenance history of
one of the plurality of input sensors.
[0020] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes adjusting the data storage profile in response to
a network resource value to move a data storage load between a
first networked device and a second networked device, wherein the
first networked device is communicatively disposed between the
second networked device and the cross point switch.
[0021] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the adjusting
includes moving the data storage load toward the first networked
device in response to at least one of the network resource value
indicating a reduced network capacity and determining the first
networked device includes sufficient storage capacity to store a
selected amount of the portion of the interrogated sensor data
until an expected network capacity increase event.
[0022] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the adjusting
includes moving the data storage load toward the second networked
device in response to the network resource value indicating a
sufficient network capacity.
[0023] The present disclosure describes monitoring apparatus for
data collection related to a chemical production process, the
apparatus according to one disclosed non-limiting embodiment of the
present disclosure can include a sensor data storage profile
component configured to determine a data storage profile, the data
storage profile including a data storage plan for the plurality of
sensor values, a sensor communication component configured to
interpret a plurality of sensor values provided at outputs a cross
point switch, each of the plurality of sensor values corresponding
to input received from at least one of a plurality of input
sensors, each of the plurality of input sensors operatively coupled
to at least one of a plurality of components of the chemical
production process and communicatively coupled to at least one
input of the cross point switch, the inputs and outputs of the
cross point switch selectively coupled based on the data storage
profile and a sensor data storage implementation component
configured to store at least a portion of the plurality of sensor
values in response to the data storage profile.
[0024] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein at least one
of the plurality of sensor values includes a sensor fusion
value.
[0025] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the data
storage profile further includes a data communication path, and
wherein the plurality of sensor data values are communicated
through a network infrastructure along the data communication
path.
[0026] Methods and systems are provided herein for data collection
in industrial environments, as well as for improved methods and
systems for using collected data to provide improved monitoring,
control, and intelligent diagnosis of problems and intelligent
optimization of operations in various heavy industrial
environments. These methods and systems include methods, systems,
components, devices, workflows, services, processes, and the like
that are deployed in various configurations and locations, such as:
(a) at the "edge" of the Internet of Things, such as in the local
environment of a heavy industrial machine; (b) in data transport
networks that move data between local environments of heavy
industrial machines and other environments, such as of other
machines or of remote controllers, such as enterprises that own or
operate the machines or the facilities in which the machines are
operated; and (c) in locations where facilities are deployed to
control machines or their environments, such as cloud-computing
environments and on-premises computing environments of enterprises
that own or control heavy industrial environments or the machines,
devices or systems deployed in them. These methods and systems
include a range of ways for providing improved data include a range
of methods and systems for providing improved data collection, as
well as methods and systems for deploying increased intelligence at
the edge, in the network, and in the cloud or premises of the
controller of an industrial environment.
[0027] Methods and systems are disclosed herein for continuous
ultrasonic monitoring, including providing continuous ultrasonic
monitoring of rotating elements and bearings of an energy
production facility; for cloud-based systems including machine
pattern recognition based on the fusion of remote, analog
industrial sensors or machine pattern analysis of state information
from multiple analog industrial sensors to provide anticipated
state information for an industrial system; for on-device sensor
fusion and data storage for industrial IoT devices, including
on-device sensor fusion and data storage for an Industrial IoT
device, where data from multiple sensors are multiplexed at the
device for storage of a fused data stream; and for self-organizing
systems including a self-organizing data marketplace for industrial
IoT data, including a self-organizing data marketplace for
industrial IoT data, where available data elements are organized in
the marketplace for consumption by consumers based on training a
self-organizing facility with a training set and feedback from
measures of marketplace success, for self-organizing data pools,
including self-organization of data pools based on utilization
and/or yield metrics, including utilization and/or yield metrics
that are tracked for a plurality of data pools, a self-organized
swarm of industrial data collectors, including a self-organizing
swarm of industrial data collectors that organize among themselves
to optimize data collection based on the capabilities and
conditions of the members of the swarm, a self-organizing
collector, including a self-organizing, multi-sensor data collector
that can optimize data collection, power and/or yield based on
conditions in its environment, a self-organizing storage for a
multi-sensor data collector, including self-organizing storage for
a multi-sensor data collector for industrial sensor data, a
self-organizing network coding for a multi-sensor data network,
including self-organizing network coding for a data network that
transports data from multiple sensors in an industrial data
collection environment.
[0028] Methods and systems are disclosed herein for training
artificial intelligence ("AI") models based on industry-specific
feedback, including training an AI model based on industry-specific
feedback that reflects a measure of utilization, yield, or impact,
where the AI model operates on sensor data from an industrial
environment; for an industrial IoT distributed ledger, including a
distributed ledger supporting the tracking of transactions executed
in an automated data marketplace for industrial IoT data; for a
network-sensitive collector, including a network
condition-sensitive, self-organizing, multi-sensor data collector
that can optimize based on bandwidth, quality of service, pricing,
and/or other network conditions; for a remotely organized universal
data collector that can power up and down sensor interfaces based
on need and/or conditions identified in an industrial data
collection environment; and for a haptic or multi-sensory user
interface, including a wearable haptic or multi-sensory user
interface for an industrial sensor data collector, with vibration,
heat, electrical, and/or sound outputs.
[0029] Methods and systems are disclosed herein for a presentation
layer for augmented reality and virtual reality (AR/VR) industrial
glasses, where heat map elements are presented based on patterns
and/or parameters in collected data; and for condition-sensitive,
self-organized tuning of AR/VR interfaces based on feedback metrics
and/or training in industrial environments.
[0030] In embodiments, a system for data collection, processing,
and utilization of signals from at least a first element in a first
machine in an industrial environment includes a platform including
a computing environment connected to a local data collection system
having at least a first sensor signal and a second sensor signal
obtained from at least the first machine in the industrial
environment. The system includes a first sensor in the local data
collection system configured to be connected to the first machine
and a second sensor in the local data collection system. The system
further includes a crosspoint switch in the local data collection
system having multiple inputs and multiple outputs including a
first input connected to the first sensor and a second input
connected to the second sensor. Throughout the present disclosure,
wherever a crosspoint switch, multiplexer (MUX) device, or other
multiple-input multiple-output data collection or communication
device is described, any multi-sensor acquisition device is also
contemplated herein. In certain embodiments, a multi-sensor
acquisition device includes one or more channels configured for, or
compatible with, an analog sensor input. The multiple outputs
include a first output and second output configured to be
switchable between a condition in which the first output is
configured to switch between delivery of the first sensor signal
and the second sensor signal and a condition in which there is
simultaneous delivery of the first sensor signal from the first
output and the second sensor signal from the second output. Each of
multiple inputs is configured to be individually assigned to any of
the multiple outputs, or combined in any subsets of the inputs to
the outputs. Unassigned outputs are configured to be switched off,
for example by producing a high-impedance state.
[0031] In embodiments, the first sensor signal and the second
sensor signal are continuous vibration data about the industrial
environment. In embodiments, the second sensor in the local data
collection system is configured to be connected to the first
machine. In embodiments, the second sensor in the local data
collection system is configured to be connected to a second machine
in the industrial environment. In embodiments, the computing
environment of the platform is configured to compare relative
phases of the first and second sensor signals. In embodiments, the
first sensor is a single-axis sensor and the second sensor is a
three-axis sensor. In embodiments, at least one of the multiple
inputs of the crosspoint switch includes internet protocol,
front-end signal conditioning, for improved signal-to-noise ratio.
In embodiments, the crosspoint switch includes a third input that
is configured with a continuously monitored alarm having a
pre-determined trigger condition when the third input is unassigned
to or undetected at any of the multiple outputs.
[0032] In embodiments, the local data collection system includes
multiple multiplexing units and multiple data acquisition units
receiving multiple data streams from multiple machines in the
industrial environment. In embodiments, the local data collection
system includes distributed complex programmable hardware device
("CPLD") chips each dedicated to a data bus for logic control of
the multiple multiplexing units and the multiple data acquisition
units that receive the multiple data streams from the multiple
machines in the industrial environment. In embodiments, the local
data collection system is configured to provide high-amperage input
capability using solid state relays. In embodiments, the local data
collection system is configured to power-down at least one of an
analog sensor channel and a component board.
[0033] In embodiments, the local data collection system includes a
phase-lock loop band-pass tracking filter configured to obtain
slow-speed revolutions per minute ("RPMs") and phase information.
In embodiments, the local data collection system is configured to
digitally derive phase using on-board timers relative to at least
one trigger channel and at least one of the multiple inputs. In
embodiments, the local data collection system includes a
peak-detector configured to autoscale using a separate
analog-to-digital converter for peak detection. In embodiments, the
local data collection system is configured to route at least one
trigger channel that is raw and buffered into at least one of the
multiple inputs. In embodiments, the local data collection system
includes at least one delta-sigma analog-to-digital converter that
is configured to increase input oversampling rates to reduce
sampling rate outputs and to minimize anti-aliasing filter
requirements. In embodiments, the distributed CPLD chips each
dedicated to the data bus for logic control of the multiple
multiplexing units and the multiple data acquisition units includes
as high-frequency crystal clock reference configured to be divided
by at least one of the distributed CPLD chips for at least one
delta-sigma analog-to-digital converter to achieve lower sampling
rates without digital resampling.
[0034] In embodiments, the local data collection system is
configured to obtain long blocks of data at a single relatively
high-sampling rate as opposed to multiple sets of data taken at
different sampling rates. In embodiments, the single relatively
high-sampling rate corresponds to a maximum frequency of about
forty kilohertz. In embodiments, the long blocks of data are for a
duration that is in excess of one minute. In embodiments, the local
data collection system includes multiple data acquisition units
each having an onboard card set configured to store calibration
information and maintenance history of a data acquisition unit in
which the onboard card set is located. In embodiments, the local
data collection system is configured to plan data acquisition
routes based on hierarchical templates.
[0035] In embodiments, the local data collection system is
configured to manage data collection bands. In embodiments, the
data collection bands define a specific frequency band and at least
one of a group of spectral peaks, a true-peak level, a crest factor
derived from a time waveform, and an overall waveform derived from
a vibration envelope. In embodiments, the local data collection
system includes a neural net expert system using intelligent
management of the data collection bands. In embodiments, the local
data collection system is configured to create data acquisition
routes based on hierarchical templates that each include the data
collection bands related to machines associated with the data
acquisition routes. In embodiments, at least one of the
hierarchical templates is associated with multiple interconnected
elements of the first machine. In embodiments, at least one of the
hierarchical templates is associated with similar elements
associated with at least the first machine and a second machine. In
embodiments, at least one of the hierarchical templates is
associated with at least the first machine being proximate in
location to a second machine.
[0036] In embodiments, the local data collection system includes a
graphical user interface ("GUI") system configured to manage the
data collection bands. In embodiments, the GUI system includes an
expert system diagnostic tool. In embodiments, the platform
includes cloud-based, machine pattern analysis of state information
from multiple sensors to provide anticipated state information for
the industrial environment. In embodiments, the platform is
configured to provide self-organization of data pools based on at
least one of the utilization metrics and yield metrics. In
embodiments, the platform includes a self-organized swarm of
industrial data collectors. In embodiments, the local data
collection system includes a wearable haptic user interface for an
industrial sensor data collector with at least one of vibration,
heat, electrical, and sound outputs.
[0037] In embodiments, multiple inputs of the crosspoint switch
include a third input connected to the second sensor and a fourth
input connected to the second sensor. The first sensor signal is
from a single-axis sensor at an unchanging location associated with
the first machine. In embodiments, the second sensor is a
three-axis sensor. In embodiments, the local data collection system
is configured to record gap-free digital waveform data
simultaneously from at least the first input, the second input, the
third input, and the fourth input. In embodiments, the platform is
configured to determine a change in relative phase based on the
simultaneously recorded gap-free digital waveform data. In
embodiments, the second sensor is configured to be movable to a
plurality of positions associated with the first machine while
obtaining the simultaneously recorded gap-free digital waveform
data. In embodiments, multiple outputs of the crosspoint switch
include a third output and fourth output. The second, third, and
fourth outputs are assigned together to a sequence of tri-axial
sensors each located at different positions associated with the
machine. In embodiments, the platform is configured to determine an
operating deflection shape based on the change in relative phase
and the simultaneously recorded gap-free digital waveform data.
[0038] In embodiments, the unchanging location is a position
associated with the rotating shaft of the first machine. In
embodiments, tri-axial sensors in the sequence of the tri-axial
sensors are each located at different positions on the first
machine but are each associated with different bearings in the
machine. In embodiments, tri-axial sensors in the sequence of the
tri-axial sensors are each located at similar positions associated
with similar bearings but are each associated with different
machines. In embodiments, the local data collection system is
configured to obtain the simultaneously recorded gap-free digital
waveform data from the first machine while the first machine and a
second machine are both in operation. In embodiments, the local
data collection system is configured to characterize a contribution
from the first machine and the second machine in the simultaneously
recorded gap-free digital waveform data from the first machine. In
embodiments, the simultaneously recorded gap-free digital waveform
data has a duration that is in excess of one minute.
[0039] In embodiments, a method of monitoring a machine having at
least one shaft supported by a set of bearings includes monitoring
a first data channel assigned to a single-axis sensor at an
unchanging location associated with the machine. The method
includes monitoring second, third, and fourth data channels each
assigned to an axis of a three-axis sensor. The method includes
recording gap-free digital waveform data simultaneously from all of
the data channels while the machine is in operation and determining
a change in relative phase based on the digital waveform data.
[0040] In embodiments, the tri-axial sensor is located at a
plurality of positions associated with the machine while obtaining
the digital waveform. In embodiments, the second, third, and fourth
channels are assigned together to a sequence of tri-axial sensors
each located at different positions associated with the machine. In
embodiments, the data is received from all of the sensors
simultaneously. In embodiments, the method includes determining an
operating deflection shape based on the change in relative phase
information and the waveform data. In embodiments, the unchanging
location is a position associated with the shaft of the machine. In
embodiments, the tri-axial sensors in the sequence of the tri-axial
sensors are each located at different positions and are each
associated with different bearings in the machine. In embodiments,
the unchanging location is a position associated with the shaft of
the machine. The tri-axial sensors in the sequence of the tri-axial
sensors are each located at different positions and are each
associated with different bearings that support the shaft in the
machine.
[0041] In embodiments, the method includes monitoring the first
data channel assigned to the single-axis sensor at an unchanging
location located on a second machine. The method includes
monitoring the second, the third, and the fourth data channels,
each assigned to the axis of a three-axis sensor that is located at
the position associated with the second machine. The method also
includes recording gap-free digital waveform data simultaneously
from all of the data channels from the second machine while both of
the machines are in operation. In embodiments, the method includes
characterizing the contribution from each of the machines in the
gap-free digital waveform data simultaneously from the second
machine.
[0042] In embodiments, a method for data collection, processing,
and utilization of signals with a platform monitoring at least a
first element in a first machine in an industrial environment
includes obtaining, automatically with a computing environment, at
least a first sensor signal and a second sensor signal with a local
data collection system that monitors at least the first machine.
The method includes connecting a first input of a crosspoint switch
of the local data collection system to a first sensor and a second
input of the crosspoint switch to a second sensor in the local data
collection system. The method includes switching between a
condition in which a first output of the crosspoint switch
alternates between delivery of at least the first sensor signal and
the second sensor signal and a condition in which there is
simultaneous delivery of the first sensor signal from the first
output and the second sensor signal from a second output of the
crosspoint switch. The method also includes switching off
unassigned outputs of the crosspoint switch into a high-impedance
state.
[0043] In embodiments, the first sensor signal and the second
sensor signal are continuous vibration data from the industrial
environment. In embodiments, the second sensor in the local data
collection system is connected to the first machine. In
embodiments, the second sensor in the local data collection system
is connected to a second machine in the industrial environment. In
embodiments, the method includes comparing, automatically with the
computing environment, relative phases of the first and second
sensor signals. In embodiments, the first sensor is a single-axis
sensor and the second sensor is a three-axis sensor. In
embodiments, at least the first input of the crosspoint switch
includes internet protocol front-end signal conditioning for
improved signal-to-noise ratio.
[0044] In embodiments, the method includes continuously monitoring
at least a third input of the crosspoint switch with an alarm
having a pre-determined trigger condition when the third input is
unassigned to any of multiple outputs on the crosspoint switch. In
embodiments, the local data collection system includes multiple
multiplexing units and multiple data acquisition units receiving
multiple data streams from multiple machines in the industrial
environment. In embodiments, the local data collection system
includes distributed CPLD chips each dedicated to a data bus for
logic control of the multiple multiplexing units and the multiple
data acquisition units that receive the multiple data streams from
the multiple machines in the industrial environment. In
embodiments, the local data collection system provides
high-amperage input capability using solid state relays.
[0045] In embodiments, the method includes powering down at least
one of an analog sensor channel and a component board of the local
data collection system. In embodiments, the local data collection
system includes an external voltage reference for an A/D zero
reference that is independent of the voltage of the first sensor
and the second sensor. In embodiments, the local data collection
system includes a phase-lock loop band-pass tracking filter that
obtains slow-speed RPMs and phase information. In embodiments, the
method includes digitally deriving phase using on-board timers
relative to at least one trigger channel and at least one of
multiple inputs on the crosspoint switch.
[0046] In embodiments, the method includes auto-scaling with a
peak-detector using a separate analog-to-digital converter for peak
detection. In embodiments, the method includes routing at least one
trigger channel that is raw and buffered into at least one of
multiple inputs on the crosspoint switch. In embodiments, the
method includes increasing input oversampling rates with at least
one delta-sigma analog-to-digital converter to reduce sampling rate
outputs and to minimize anti-aliasing filter requirements. In
embodiments, the distributed CPLD chips are each dedicated to the
data bus for logic control of the multiple multiplexing units and
the multiple data acquisition units and each include a
high-frequency crystal clock reference divided by at least one of
the distributed CPLD chips for at least one delta-sigma
analog-to-digital converter to achieve lower sampling rates without
digital resampling. In embodiments, the method includes obtaining
long blocks of data at a single relatively high-sampling rate with
the local data collection system as opposed to multiple sets of
data taken at different sampling rates. In embodiments, the single
relatively high-sampling rate corresponds to a maximum frequency of
about forty kilohertz. In embodiments, the long blocks of data are
for a duration that is in excess of one minute. In embodiments, the
local data collection system includes multiple data acquisition
units and each data acquisition unit has an onboard card set that
stores calibration information and maintenance history of a data
acquisition unit in which the onboard card set is located.
[0047] In embodiments, the method includes planning data
acquisition routes based on hierarchical templates associated with
at least the first element in the first machine in the industrial
environment. In embodiments, the local data collection system
manages data collection bands that define a specific frequency band
and at least one of a group of spectral peaks, a true-peak level, a
crest factor derived from a time waveform, and an overall waveform
derived from a vibration envelope. In embodiments, the local data
collection system includes a neural net expert system using
intelligent management of the data collection bands. In
embodiments, the local data collection system creates data
acquisition routes based on hierarchical templates that each
include the data collection bands related to machines associated
with the data acquisition routes. In embodiments, at least one of
the hierarchical templates is associated with multiple
interconnected elements of the first machine. In embodiments, at
least one of the hierarchical templates is associated with similar
elements associated with at least the first machine and a second
machine. In embodiments, at least one of the hierarchical templates
is associated with at least the first machine being proximate in
location to a second machine.
[0048] In embodiments, the method includes controlling a GUI system
of the local data collection system to manage the data collection
bands. The GUI system includes an expert system diagnostic tool. In
embodiments, the computing environment of the platform includes
cloud-based, machine pattern analysis of state information from
multiple sensors to provide anticipated state information for the
industrial environment. In embodiments, the computing environment
of the platform provides self-organization of data pools based on
at least one of the utilization metrics and yield metrics. In
embodiments, the computing environment of the platform includes a
self-organized swarm of industrial data collectors. In embodiments,
each of multiple inputs of the crosspoint switch is individually
assignable to any of multiple outputs of the crosspoint switch.
[0049] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing and storage systems and may include a method for
capturing a plurality of streams of sensed data from sensors
deployed to monitor aspects of an industrial machine associated
with at least one moving part of the machine; at least one of the
streams contains a plurality of frequencies of data. The method may
include identifying a subset of data in at least one of the
plurality of streams that corresponds to data representing at least
one predefined frequency. The at least one predefined frequency is
represented by a set of data collected from alternate sensors
deployed to monitor aspects of the industrial machine associated
with the at least one moving part of the machine. The method may
further include processing the identified data with a data
processing facility that processes the identified data with an
algorithm configured to be applied to the set of data collected
from alternate sensors. Lastly, the method may include storing the
at least one of the streams of data, the identified subset of data,
and a result of processing the identified data in an electronic
data set.
[0050] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing, and storage systems and may include a method for
applying data captured from sensors deployed to monitor aspects of
an industrial machine associated with at least one moving part of
the machine. The data is captured with predefined lines of
resolution covering a predefined frequency range and is sent to a
frequency matching facility that identifies a subset of data
streamed from other sensors deployed to monitor aspects of the
industrial machine associated with at least one moving part of the
machine. The streamed data includes a plurality of lines of
resolution and frequency ranges. The subset of data identified
corresponds to the lines of resolution and predefined frequency
range. This method may include storing the subset of data in an
electronic data record in a format that corresponds to a format of
the data captured with predefined lines of resolution and signaling
to a data processing facility the presence of the stored subset of
data. This method may, optionally, include processing the subset of
data with at least one set of algorithms, models and pattern
recognizers that corresponds to algorithms, models and pattern
recognizers associated with processing the data captured with
predefined lines of resolution covering a predefined frequency
range.
[0051] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing and storage systems and may include a method for
identifying a subset of streamed sensor data, the sensor data
captured from sensors deployed to monitor aspects of an industrial
machine associated with at least one moving part of the machine,
the subset of streamed sensor data at predefined lines of
resolution for a predefined frequency range, and establishing a
first logical route for communicating electronically between a
first computing facility performing the identifying and a second
computing facility, wherein identified subset of the streamed
sensor data is communicated exclusively over the established first
logical route when communicating the subset of streamed sensor data
from the first facility to the second facility. This method may
further include establishing a second logical route for
communicating electronically between the first computing facility
and the second computing facility for at least one portion of the
streamed sensor data that is not the identified subset.
Additionally, this method may further include establishing a third
logical route for communicating electronically between the first
computing facility and the second computing facility for at least
one portion of the streamed sensor data that includes the
identified subset and at least one other portion of the data not
represented by the identified subset.
[0052] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing and storage systems and may include a first data sensing
and processing system that captures first data from a first set of
sensors deployed to monitor aspects of an industrial machine
associated with at least one moving part of the machine, the first
data covering a set of lines of resolution and a frequency range.
This system may include a second data sensing and processing system
that captures and streams a second set of data from a second set of
sensors deployed to monitor aspects of the industrial machine
associated with at least one moving part of the machine, the second
data covering a plurality of lines of resolution that includes the
set of lines of resolution and a plurality of frequencies that
includes the frequency range. The system may enable selecting a
portion of the second data that corresponds to the set of lines of
resolution and the frequency range of the first data, and
processing the selected portion of the second data with the first
data sensing and processing system.
[0053] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing and storage systems and may include a method for
automatically processing a portion of a stream of sensed data. The
sensed data is received from a first set of sensors deployed to
monitor aspects of an industrial machine associated with at least
one moving part of the machine. The sensed data is in response to
an electronic data structure that facilitates extracting a subset
of the stream of sensed data that corresponds to a set of sensed
data received from a second set of sensors deployed to monitor the
aspects of the industrial machine associated with the at least one
moving part of the machine. The set of sensed data is constrained
to a frequency range. The stream of sensed data includes a range of
frequencies that exceeds the frequency range of the set of sensed
data, the processing comprising executing an algorithm on a portion
of the stream of sensed data that is constrained to the frequency
range of the set of sensed data, the algorithm configured to
process the set of sensed data.
[0054] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing and storage systems and may include a method for
receiving first data from sensors deployed to monitor aspects of an
industrial machine associated with at least one moving part of the
machine. This method may further include detecting at least one of
a frequency range and lines of resolution represented by the first
data; receiving a stream of data from sensors deployed to monitor
the aspects of the industrial machine associated with the at least
one moving part of the machine. The stream of data includes: (1) a
plurality of frequency ranges and a plurality of lines of
resolution that exceeds the frequency range and the lines of
resolution represented by the first data; (2) a set of data
extracted from the stream of data that corresponds to at least one
of the frequency range and the lines of resolution represented by
the first data; and (3) the extracted set of data which is
processed with a data processing algorithm that is configured to
process data within the frequency range and within the lines of
resolution of the first data.
BRIEF DESCRIPTION OF THE FIGURES
[0055] FIG. 1 through FIG. 5 are diagrammatic views that each
depicts portions of an overall view of an industrial Internet of
Things (IoT) data collection, monitoring and control system in
accordance with the present disclosure.
[0056] FIG. 6 is a diagrammatic view of a platform including a
local data collection system disposed in an industrial environment
for collecting data from or about the elements of the environment,
such as machines, components, systems, sub-systems, ambient
conditions, states, workflows, processes, and other elements in
accordance with the present disclosure.
[0057] FIG. 7 is a diagrammatic view that depicts elements of an
industrial data collection system for collecting analog sensor data
in an industrial environment in accordance with the present
disclosure.
[0058] FIG. 8 is a diagrammatic view of a rotating or oscillating
machine having a data acquisition module that is configured to
collect waveform data in accordance with the present
disclosure.
[0059] FIG. 9 is a diagrammatic view of an exemplary tri-axial
sensor mounted to a motor bearing of an exemplary rotating machine
in accordance with the present disclosure.
[0060] FIG. 10 and FIG. 11 are diagrammatic views of an exemplary
tri-axial sensor and a single-axis sensor mounted to an exemplary
rotating machine in accordance with the present disclosure.
[0061] FIG. 12 is a diagrammatic view of multiple machines under
survey with ensembles of sensors in accordance with the present
disclosure.
[0062] FIG. 13 is a diagrammatic view of hybrid relational metadata
and a binary storage approach in accordance with the present
disclosure.
[0063] FIG. 14 is a diagrammatic view of components and
interactions of a data collection architecture involving
application of cognitive and machine learning systems to data
collection and processing in accordance with the present
disclosure.
[0064] FIG. 15 is a diagrammatic view of components and
interactions of a data collection architecture involving
application of a platform having a cognitive data marketplace in
accordance with the present disclosure.
[0065] FIG. 16 is a diagrammatic view of components and
interactions of a data collection architecture involving
application of a self-organizing swarm of data collectors in
accordance with the present disclosure.
[0066] FIG. 17 is a diagrammatic view of components and
interactions of a data collection architecture involving
application of a haptic user interface in accordance with the
present disclosure.
[0067] FIG. 18 is a diagrammatic view of a multi-format streaming
data collection system in accordance with the present
disclosure.
[0068] FIG. 19 is a diagrammatic view of combining legacy and
streaming data collection and storage in accordance with the
present disclosure.
[0069] FIG. 20 is a diagrammatic view of industrial machine sensing
using both legacy and updated streamed sensor data processing in
accordance with the present disclosure.
[0070] FIG. 21 is a diagrammatic view of an industrial machine
sensed data processing system that facilitates portal algorithm use
and alignment of legacy and streamed sensor data in accordance with
the present disclosure.
[0071] FIG. 22 is a diagrammatic view of components and
interactions of a data collection architecture involving a
streaming data acquisition instrument receiving analog sensor
signals from an industrial environment connected to a cloud network
facility in accordance with the present disclosure.
[0072] FIG. 23 is a diagrammatic view of components and
interactions of a data collection architecture involving a
streaming data acquisition instrument having an alarms module,
expert analysis module, and a driver API to facilitate
communication with a cloud network facility in accordance with the
present disclosure.
[0073] FIG. 24 is a diagrammatic view of components and
interactions of a data collection architecture involving a
streaming data acquisition instrument and first in, first out
memory architecture to provide a real time operating system in
accordance with the present disclosure.
[0074] FIG. 25 through FIG. 30 are diagrammatic views of screens
showing four analog sensor signals, transfer functions between the
signals, analysis of each signal, and operating controls to move
and edit throughout the streaming signals obtained from the sensors
in accordance with the present disclosure.
[0075] FIG. 31 is a diagrammatic view of components and
interactions of a data collection architecture involving a multiple
streaming data acquisition instrument receiving analog sensor
signals and digitizing those signals to be obtained by a streaming
hub server in accordance with the present disclosure.
[0076] FIG. 32 is a diagrammatic view of components and
interactions of a data collection architecture involving a master
raw data server that processes new streaming data and data already
extracted and processed in accordance with the present
disclosure.
[0077] FIG. 33, FIG. 34, and FIG. 35 are diagrammatic views of
components and interactions of a data collection architecture
involving a processing, analysis, report, and archiving server that
processes new streaming data and data already extracted and
processed in accordance with the present disclosure.
[0078] FIG. 36 is a diagrammatic view of components and
interactions of a data collection architecture involving a relation
database server and data archives and their connectivity with a
cloud network facility in accordance with the present
disclosure.
[0079] FIG. 37 through FIG. 42 are diagrammatic views of components
and interactions of a data collection architecture involving a
virtual streaming data acquisition instrument receiving analog
sensor signals from an industrial environment connected to a cloud
network facility in accordance with the present disclosure.
[0080] FIG. 43 through FIG. 50 are diagrammatic views of components
and interactions of a data collection architecture involving data
channel methods and systems for data collection of industrial
machines in accordance with the present disclosure.
[0081] FIG. 51 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0082] FIG. 52 and FIG. 53 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0083] FIG. 54 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0084] FIGS. 55 and 56 are diagrammatic views that depict an
embodiment of a system for data collection in accordance with the
present disclosure.
[0085] FIGS. 57 and 58 are diagrammatic views that depict an
embodiment of a system for data collection comprising a plurality
of data monitoring devices in accordance with the present
disclosure.
[0086] FIG. 59 depicts an embodiment of a data monitoring device
incorporating sensors in accordance with the present
disclosure.
[0087] FIGS. 60 and 61 are diagrammatic views that depict
embodiments of a data monitoring device in communication with
external sensors in accordance with the present disclosure.
[0088] FIG. 62 is a diagrammatic view that depicts embodiments of a
data monitoring device with additional detail in the signal
evaluation circuit in accordance with the present disclosure.
[0089] FIG. 63 is a diagrammatic view that depicts embodiments of a
data monitoring device with additional detail in the signal
evaluation circuit in accordance with the present disclosure.
[0090] FIG. 64 is a diagrammatic view that depicts embodiments of a
data monitoring device with additional detail in the signal
evaluation circuit in accordance with the present disclosure.
[0091] FIG. 65 is a diagrammatic view that depicts embodiments of a
system for data collection in accordance with the present
disclosure.
[0092] FIG. 66 is a diagrammatic view that depicts embodiments of a
system for data collection comprising a plurality of data
monitoring devices in accordance with the present disclosure.
[0093] FIG. 67 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0094] FIGS. 68 and 69 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0095] FIGS. 70 and 71 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0096] FIGS. 72 and 73 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0097] FIGS. 74 and 75 is a diagrammatic view that depicts
embodiments of a system for data collection comprising a plurality
of data monitoring devices in accordance with the present
disclosure.
[0098] FIG. 76 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0099] FIGS. 77 and 78 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0100] FIG. 79 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0101] FIG. 80 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0102] FIGS. 81 and 82 are diagrammatic views that depict
embodiments of a system for data collection in accordance with the
present disclosure.
[0103] FIGS. 83 and 84 are diagrammatic views that depict
embodiments of a system for data collection comprising a plurality
of data monitoring devices in accordance with the present
disclosure.
[0104] FIG. 85 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0105] FIGS. 86 and 87 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0106] FIG. 88 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0107] FIGS. 89 and 90 are diagrammatic views that depict
embodiments of a system for data collection in accordance with the
present disclosure.
[0108] FIGS. 91 and 92 are diagrammatic views that depict
embodiments of a system for data collection comprising a plurality
of data monitoring devices in accordance with the present
disclosure.
[0109] FIG. 93 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0110] FIGS. 94 and 95 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0111] FIG. 96 is a diagrammatic view that depicts embodiments of a
data monitoring device in accordance with the present
disclosure.
[0112] FIGS. 97 and 98 are diagrammatic views that depict
embodiments of a system for data collection in accordance with the
present disclosure.
[0113] FIGS. 99 and 100 are diagrammatic views that depict
embodiments of a system for data collection comprising a plurality
of data monitoring devices in accordance with the present
disclosure.
[0114] FIG. 101 is a diagrammatic view that depicts embodiments of
a data monitoring device in accordance with the present
disclosure.
[0115] FIGS. 102 and 103 are diagrammatic views that depict
embodiments of a data monitoring device in accordance with the
present disclosure.
[0116] FIG. 104 is a diagrammatic view that depicts embodiments of
a data monitoring device in accordance with the present
disclosure.
[0117] FIGS. 105 and 106 are diagrammatic views that depict
embodiments of a system for data collection in accordance with the
present disclosure.
[0118] FIGS. 107 and 108 are diagrammatic views that depict
embodiments of a system for data collection comprising a plurality
of data monitoring devices in accordance with the present
disclosure.
[0119] FIG. 109 to FIG. 136 are diagrammatic views of components
and interactions of a data collection architecture involving
various neural network embodiments interacting with a streaming
data acquisition instrument receiving analog sensor signals and an
expert analysis module in accordance with the present
disclosure.
[0120] FIG. 137 through FIG. 139 are diagrammatic views of
components and interactions of a data collection architecture
involving a collector of route templates and the routing of data
collectors in an industrial environment in accordance with the
present disclosure.
[0121] FIG. 140 is a diagrammatic view that depicts a monitoring
system that employs data collection bands in accordance with the
present disclosure.
[0122] FIG. 141 is a diagrammatic view that depicts a system that
employs vibration and other noise in predicting states and outcomes
in accordance with the present disclosure.
[0123] FIG. 142 is a diagrammatic view that depicts a system for
data collection in an industrial environment in accordance with the
present disclosure.
[0124] FIG. 143 is a diagrammatic view that depicts an apparatus
for data collection in an industrial environment in accordance with
the present disclosure.
[0125] FIG. 144 is a schematic flow diagram of a procedure for data
collection in an industrial environment in accordance with the
present disclosure.
[0126] FIG. 145 is a diagrammatic view that depicts a system for
data collection in an industrial environment in accordance with the
present disclosure.
[0127] FIG. 146 is a diagrammatic view that depicts an apparatus
for data collection in an industrial environment in accordance with
the present disclosure.
[0128] FIG. 147 is a schematic flow diagram of a procedure for data
collection in an industrial environment in accordance with the
present disclosure.
[0129] FIG. 148 is a diagrammatic view that depicts
industry-specific feedback in an industrial environment in
accordance with the present disclosure.
[0130] FIG. 149 is a diagrammatic view that depicts an exemplary
user interface for smart band configuration of a system for data
collection in an industrial environment is depicted in accordance
with the present disclosure.
[0131] FIG. 150 is a diagrammatic view that depicts a graphical
approach 11300 for back-calculation in accordance with the present
disclosure.
[0132] FIG. 151 is a diagrammatic view that depicts a wearable
haptic user interface device for providing haptic stimuli to a user
that is responsive to data collected in an industrial environment
by a system adapted to collect data in the industrial environment
in accordance with the present disclosure.
[0133] FIG. 152 is a diagrammatic view that depicts an augmented
reality display of heat maps based on data collected in an
industrial environment by a system adapted to collect data in the
environment in accordance with the present disclosure.
[0134] FIG. 153 is a diagrammatic view that depicts an augmented
reality display including real time data overlaying a view of an
industrial environment in accordance with the present
disclosure.
[0135] FIG. 154 is a diagrammatic view that depicts a user
interface display and components of a neural net in a graphical
user interface in accordance with the present disclosure.
[0136] FIG. 155 is a diagrammatic view of components and
interactions of a data collection architecture involving swarming
data collectors and sensor mesh protocol in an industrial
environment in accordance with the present disclosure.
[0137] FIG. 156 through FIG. 159 are diagrammatic views mobile
sensors platforms in an industrial environment in accordance with
the present disclosure.
[0138] FIG. 160 is a diagrammatic view of components and
interactions of a data collection architecture involving two mobile
sensor platforms inspecting a vehicle during assembly in an
industrial environment in accordance with the present
disclosure.
[0139] FIG. 161 and FIG. 162 are diagrammatic views one of the
mobile sensor platforms in an industrial environment in accordance
with the present disclosure.
[0140] FIG. 163 is a diagrammatic view of components and
interactions of a data collection architecture involving two mobile
sensor platforms inspecting a turbine engine during assembly in an
industrial environment in accordance with the present
disclosure.
[0141] FIG. 164 is a diagrammatic view that depicts data collection
system according to some aspects of the present disclosure.
[0142] FIG. 165 is a diagrammatic view that depicts a system for
self-organized, network-sensitive data collection in an industrial
environment in accordance with the present disclosure.
[0143] FIG. 166 is a diagrammatic view that depicts an apparatus
for self-organized, network-sensitive data collection in an
industrial environment in accordance with the present
disclosure.
[0144] FIG. 167 is a diagrammatic view that depicts an apparatus
for self-organized, network-sensitive data collection in an
industrial environment in accordance with the present
disclosure.
[0145] FIG. 168 is a diagrammatic view that depicts an apparatus
for self-organized, network-sensitive data collection in an
industrial environment in accordance with the present
disclosure.
[0146] FIG. 169 and FIG. 170 are diagrammatic views that depict
embodiments of transmission conditions in accordance with the
present disclosure.
[0147] FIG. 171 is a diagrammatic view that depicts embodiments of
a sensor data transmission protocol in accordance with the present
disclosure.
[0148] FIG. 172 and FIG. 173 are diagrammatic views that depict
embodiments of benchmarking data in accordance with the present
disclosure.
[0149] FIG. 174 is a diagrammatic view that depicts embodiments of
a system for data collection and storage in an industrial
environment in accordance with the present disclosure.
[0150] FIG. 175 is a diagrammatic view that depicts embodiments of
an apparatus for self-organizing storage for data collection for an
industrial system in accordance with the present disclosure.
[0151] FIG. 176 is a diagrammatic view that depicts embodiments of
a storage time definition in accordance with the present
disclosure.
[0152] FIG. 177 is a diagrammatic view that depicts embodiments of
a data resolution description in accordance with the present
disclosure.
[0153] FIG. 178 and FIG. 179 diagrammatic views of an apparatus for
self-organizing network coding for data collection for an
industrial system in accordance with the present disclosure.
[0154] FIG. 180 and FIG. 181 diagrammatic views of data marketplace
interacting with data collection in an industrial system in
accordance with the present disclosure.
[0155] FIG. 182 is a diagrammatic view that depicts a smart heating
system as an element in a network for in an industrial Internet of
Things ecosystem in accordance with the present disclosure.
[0156] FIG. 183 is a schematic of a data network including server
and client nodes coupled by intermediate networks.
[0157] FIG. 184 is a block diagram illustrating the modules that
implement TCP-based communication between a client node and a
server node.
[0158] FIG. 185 is a block diagram illustrating the modules that
implement Packet Coding Transmission Communication Protocol
(PC-TCP) based communication between a client node and a server
node.
[0159] FIG. 186 is a schematic diagram of a use of the PC-TCP based
communication between a server and a module device on a cellular
network.
[0160] FIG. 187 is a block diagram of 1 PC-TCP module that uses a
conventional UDP module.
[0161] FIG. 188 is a block diagram of a PC-TCP module that is
partially integrated into a client application and partially
implemented using a conventional UDP module.
[0162] FIG. 189 is a block diagram or a PC-TCP module that is split
with user space and kernel space components.
[0163] FIG. 190 is a block diagram for a proxy architecture.
[0164] FIG. 191 is a block diagram of a PC-TCP based proxy
architecture in which a proxy node communicates using both PC-TCP
and conventional TCP.
[0165] FIG. 192 is a block diagram of a PC-TCP proxy-based
architecture embodied using a gateway device.
[0166] FIG. 193 is a block diagram of an alternative proxy
architecture embodied within a client node.
[0167] FIG. 194 is a block diagram of a second PC-TCP based proxy
architecture in which a proxy node communicates using both PC-TCP
and conventional TCP.
[0168] FIG. 195 is a block diagram of a PC-TCP proxy-based
architecture embodied using a wireless access device.
[0169] FIG. 196 is a block diagram of a PC-TCP proxy-based
architecture embodied cellular network.
[0170] FIG. 197 is a block diagram of a PC-TCP proxy-based
architecture embodied cable television-based data network.
[0171] FIG. 198 is a block diagram of an intermediate proxy that
communicates with a client node and with a server node using
separate PC-TCP connections.
[0172] FIG. 199 is a block diagram of a PC-TCP proxy-based
architecture embodied in a network device.
[0173] FIG. 200 is a block diagram of an intermediate proxy that
recodes communication between a client node and with a server
node.
[0174] FIGS. 201-202 are diagrams that illustrates delivery of
common content to multiple destinations.
[0175] FIGS. 203-213 are schematic diagrams of various embodiments
of PC-TCP communication approaches.
[0176] FIG. 214 is a block diagram of PC-TCP communication approach
that includes window and rate control modules.
[0177] FIG. 215 is a schematic of a data network.
[0178] FIGS. 216-219 are block diagrams illustrating an embodiment
PC-TCP communication approach that is configured according to a
number of tunable parameters.
[0179] FIG. 220 is a diagram showing a network communication
system.
[0180] FIG. 221 is a schematic diagram illustrating use of stored
communication parameters.
[0181] FIG. 222 is a schematic diagram illustrating a first
embodiment or multi-path content delivery.
[0182] FIGS. 223-225 are schematic diagrams illustrating a second
embodiment of multi-path content delivery.
[0183] FIG. 226 is a diagrammatic view depicting an integrated
cooktop of intelligent cooking system methods and systems in
accordance with the present teachings.
[0184] FIG. 227 is a diagrammatic view depicting a single
intelligent burner of the intelligent cooking system in accordance
with the present teachings.
[0185] FIG. 228 is a partial exterior view depicting a
solar-powered hydrogen production and storage station in accordance
with the present teachings.
[0186] FIG. 229 is a diagrammatic view depicting a low-pressure
storage system in accordance with the present teachings.
[0187] FIG. 230 and FIG. 231 are cross-sectional views of a
low-pressure storage system.
[0188] FIG. 232 is a diagrammatic view depicting an electrolyzer in
accordance with the present teachings.
[0189] FIG. 233 is a diagrammatic view depicting features of a
platform that interact with electronic devices and participants in
a related ecosystem of suppliers, content providers, service
providers, and regulators in accordance with the present
teachings.
[0190] FIG. 234 is a diagrammatic view depicting a smart home
embodiment of the intelligent cooking system in accordance with the
present teachings.
[0191] FIG. 235 is a diagrammatic view depicting a hydrogen
production and use system in accordance with the present
teachings.
[0192] FIG. 236 is a diagrammatic view depicting an electrolytic
cell in accordance with the present teachings.
[0193] FIG. 237 is a diagrammatic view depicting a hydrogen
production system integrated into a cooking system in accordance
with the present teachings.
[0194] FIG. 238 is a diagrammatic view depicting auto switching
connectivity in the form of ad hoc Wi-Fi from the cooktop through
nearby mobile devices in a normal connectivity mode when Wi-Fi is
available in accordance with the present teachings.
[0195] FIG. 239 is a diagrammatic view depicting an auto switching
connectivity in the form of ad hoc Wi Fi from the cooktop through
nearby mobile devices for ad hoc use of the local mobile devices
for connectivity to the cloud in accordance with the present
teachings.
[0196] FIG. 240 is a perspective view depicting a three-element
induction smart cooking system in accordance with the present
teachings.
[0197] FIG. 241 is a perspective view depicting a single burner gas
smart cooking system in accordance with the present teachings.
[0198] FIG. 242 is a perspective view depicting an electric hot
plate smart cooking system in accordance with the present
teachings.
[0199] FIG. 243 is a perspective view depicting a single induction
heating element smart cooking system in accordance with the present
teachings.
[0200] FIGS. 244-251 are views of visual interfaces depicting user
interface features of a smart knob in accordance with the present
teachings.
[0201] FIG. 252 is a perspective view depicting a smart knob
deployed on a single heating element cooking system in accordance
with the present teachings.
[0202] FIG. 253 is a partial perspective view depicting a smart
knob deployed on a side of a kitchen appliance for a single heating
element cooking system in accordance with the present
teachings.
[0203] FIGS. 254-257 are perspective views depicting smart
temperature probes of the smart cooking system in accordance with
the present teachings.
[0204] FIGS. 258-263 are diagrammatic views depicting different
docks for compatibility with a range of smart phone and tablet
devices in accordance with the present teachings.
[0205] FIG. 264 and FIG. 266 are diagrammatic views depicting a
burner design contemplated for use with a smart cooking system in
accordance with the present teachings.
[0206] FIG. 265 is a cross sectional view of a burner design
contemplated for use with a smart cooking system.
[0207] FIG. 267, FIG. 269, and FIG. 271 are diagrammatic views
depicting a burner design contemplated for use with a smart cooking
system. in accordance with another example of the present
teachings.
[0208] FIG. 268 and FIG. 270 are cross-sectional views of a burner
design.
[0209] FIGS. 272-274 are diagrammatic views depicting a burner
design contemplated for use with a smart cooking system in
accordance with a further example of the present teachings.
[0210] FIGS. 275-277 are diagrammatic views depicting a burner
design contemplated for use with a smart cooking system in
accordance with yet another example of the present teachings.
[0211] FIG. 278 and FIG. 280 are diagrammatic views depicting a
burner design contemplated for use with a smart cooking system in
accordance with an additional example of the present teachings.
[0212] FIG. 279 is a cross-sectional view of a burner design
contemplated for use with a smart cooking system.
[0213] FIG. 281 is a flowchart depicting a method associated with a
smart kitchen including a smart cooktop and an exhaust fan that may
be automatically turned on as water in a pot may begin to boil in
accordance with the present teachings.
[0214] FIG. 282 is an embodiment method and system related to
renewable energy sources for hydrogen production, storage,
distribution and use are depicted in accordance with the present
teachings in accordance with the present teachings.
[0215] FIG. 283 is an alternate embodiment method and system
related to renewable energy sources in accordance with the present
teachings.
[0216] FIG. 284 is an alternate embodiment method and system
related to renewable energy sources in accordance with the present
teachings.
[0217] FIG. 285 depicts environments and manufacturing uses of
hydrogen production. storage, distribution and use systems.
DETAILED DESCRIPTION
[0218] Detailed embodiments of the present disclosure are disclosed
herein; however, it is to be understood that the disclosed
embodiments are merely exemplary of the disclosure, which may be
embodied in various forms. Therefore, specific structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present disclosure in virtually any
appropriately detailed structure.
[0219] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate with existing data collection, processing,
and storage systems while preserving access to existing
format/frequency range/resolution compatible data. While the
industrial machine sensor data streaming facilities described
herein may collect a greater volume of data (e.g., longer duration
of data collection) from sensors at a wider range of frequencies
and with greater resolution than existing data collection systems,
methods and systems may be employed to provide access to data from
the stream of data that represents one or more ranges of frequency
and/or one or more lines of resolution that are purposely
compatible with existing systems. Further, a portion of the
streamed data may be identified, extracted, stored, and/or
forwarded to existing data processing systems to facilitate
operation of existing data processing systems that substantively
matches operation of existing data processing systems using
existing collection-based data. In this way, a newly deployed
system for sensing aspects of industrial machines, such as aspects
of moving parts of industrial machines, may facilitate continued
use of existing sensed data processing facilities, algorithms,
models, pattern recognizers, user interfaces, and the like.
[0220] Through identification of existing frequency ranges,
formats, and/or resolution, such as by accessing a data structure
that defines these aspects of existing data, higher resolution
streamed data may be configured to represent a specific frequency,
frequency range, format, and/or resolution. This configured
streamed data can be stored in a data structure that is compatible
with existing sensed data structures so that existing processing
systems and facilities can access and process the data
substantially as if it were the existing data. One approach to
adapting streamed data for compatibility with existing sensed data
may include aligning the streamed data with existing data so that
portions of the streamed data that align with the existing data can
be extracted, stored, and made available for processing with
existing data processing methods. Alternatively, data processing
methods may be configured to process portions of the streamed data
that correspond, such as through alignment, to the existing data,
with methods that implement functions substantially similar to the
methods used to process existing data, such as methods that process
data that contain a particular frequency range or a particular
resolution and the like.
[0221] Methods used to process existing data may be associated with
certain characteristics of sensed data, such as certain frequency
ranges, sources of data, and the like. As an example, methods for
processing bearing sensing information for a moving part of an
industrial machine may be capable of processing data from bearing
sensors that fall into a particular frequency range. This method
can thusly be at least partially identifiable by these
characteristics of the data being processed. Therefore, given a set
of conditions, such as moving device being sensed, industrial
machine type, frequency of data being sensed, and the like, a data
processing system may select an appropriate method. Also, given
such a set of conditions, an industrial machine data sensing and
processing facility may configure elements, such as data filters,
routers, processors, and the like, to handle data meeting the
conditions.
[0222] FIGS. 1 through 5 depict portions of an overall view of an
industrial Internet of Things (IoT) data collection, monitoring and
control system 10. FIG. 2 depicts a mobile ad hoc network ("MANET")
20, which may form a secure, temporal network connection 22
(sometimes connected and sometimes isolated), with a cloud 30 or
other remote networking system, so that network functions may occur
over the MANET 20 within the environment, without the need for
external networks, but at other times information can be sent to
and from a central location. This allows the industrial environment
to use the benefits of networking and control technologies, while
also providing security, such as preventing cyber-attacks. The
MANET 20 may use cognitive radio technologies 40, including those
that form up an equivalent to the IP protocol, such as router 42,
MAC 44, and physical layer technologies 46. In certain embodiments,
the system depicted in FIGS. 1 through 5 provides network-sensitive
or network-aware transport of data over the network to and from a
data collection device or a heavy industrial machine.
[0223] FIGS. 3-4 depict intelligent data collection technologies
deployed locally, at the edge of an IoT deployment, where heavy
industrial machines are located. This includes various sensors 52,
IoT devices 54, data storage capabilities (e.g., data pools 60, or
distributed ledger 62) (including intelligent, self-organizing
storage), sensor fusion (including self-organizing sensor fusion),
and the like. Interfaces for data collection, including
multi-sensory interfaces, tablets, smartphones 58, and the like are
shown. FIG. 3 also shows data pools 60 that may collect data
published by machines or sensors that detect conditions of
machines, such as for later consumption by local or remote
intelligence. A distributed ledger system 62 may distribute storage
across the local storage of various elements of the environment, or
more broadly throughout the system. FIG. 4 also shows on-device
sensor fusion 80, such as for storing on a device data from
multiple analog sensors 82, which may be analyzed locally or in the
cloud, such as by machine learning 84, including by training a
machine based on initial models created by humans that are
augmented by providing feedback (such as based on measures of
success) when operating the methods and systems disclosed
herein.
[0224] FIG. 1 depicts a server based portion of an industrial IoT
system that may be deployed in the cloud or on an enterprise
owner's or operator's premises. The server portion includes network
coding (including self-organizing network coding and/or automated
configuration) that may configure a network coding model based on
feedback measures, network conditions, or the like, for highly
efficient transport of large amounts of data across the network to
and from data collection systems and the cloud. Network coding may
provide a wide range of capabilities for intelligence, analytics,
remote control, remote operation, remote optimization, various
storage configurations and the like, as depicted in FIG. 1. The
various storage configurations may include distributed ledger
storage for supporting transactional data or other elements of the
system.
[0225] FIG. 5 depicts a programmatic data marketplace 70, which may
be a self-organizing marketplace, such as for making available data
that is collected in industrial environments, such as from data
collectors, data pools, distributed ledgers, and other elements
disclosed herein. Additional detail on the various components and
sub-components of FIGS. 1 through 5 is provided throughout this
disclosure.
[0226] With reference to FIG. 6, an embodiment of platform 100 may
include a local data collection system 102, which may be disposed
in an environment 104, such as an industrial environment similar to
that shown in FIG. 3, for collecting data from or about the
elements of the environment, such as machines, components, systems,
sub-systems, ambient conditions, states, workflows, processes, and
other elements. The platform 100 may connect to or include portions
of the industrial IoT data collection, monitoring and control
system 10 depicted in FIGS. 1-5. The platform 100 may include a
network data transport system 108, such as for transporting data to
and from the local data collection system 102 over a network 110,
such as to a host processing system 112, such as one that is
disposed in a cloud computing environment or on the premises of an
enterprise, or that consists of distributed components that
interact with each other to process data collected by the local
data collection system 102. The host processing system 112,
referred to for convenience in some cases as the host system 112,
may include various systems, components, methods, processes,
facilities, and the like for enabling automated, or
automation-assisted processing of the data, such as for monitoring
one or more environments 104 or networks 110 or for remotely
controlling one or more elements in a local environment 104 or in a
network 110. The platform 100 may include one or more local
autonomous systems, such as for enabling autonomous behavior, such
as reflecting artificial, or machine-based intelligence or such as
enabling automated action based on the applications of a set of
rules or models upon input data from the local data collection
system 102 or from one or more input sources 116, which may
comprise information feeds and inputs from a wide array of sources,
including those in the local environment 104, in a network 110, in
the host system 112, or in one or more external systems, databases,
or the like. The platform 100 may include one or more intelligent
systems 118, which may be disposed in, integrated with, or acting
as inputs to one or more components of the platform 100. Details of
these and other components of the platform 100 are provided
throughout this disclosure.
[0227] Intelligent systems 118 may include cognitive systems 120,
such as enabling a degree of cognitive behavior as a result of the
coordination of processing elements, such as mesh, peer-to-peer,
ring, serial, and other architectures, where one or more node
elements is coordinated with other node elements to provide
collective, coordinated behavior to assist in processing,
communication, data collection, or the like. The MANET 20 depicted
in FIG. 2 may also use cognitive radio technologies, including
those that form up an equivalent to the IP protocol, such as router
42, MAC 44, and physical layer technologies 46. In one example, the
cognitive system technology stack can include examples disclosed in
U.S. Pat. No. 8,060,017 to Schlicht et al., issued 15 Nov. 2011 and
hereby incorporated by reference as if fully set forth herein.
[0228] Intelligent systems may include machine learning systems
122, such as for learning on one or more data sets. The one or more
data sets may include information collected using local data
collection systems 102 or other information from input sources 116,
such as to recognize states, objects, events, patterns, conditions,
or the like that may, in turn, be used for processing by the host
system 112 as inputs to components of the platform 100 and portions
of the industrial IoT data collection, monitoring and control
system 10, or the like. Learning may be human-supervised or
fully-automated, such as using one or more input sources 116 to
provide a data set, along with information about the item to be
learned. Machine learning may use one or more models, rules,
semantic understandings, workflows, or other structured or
semi-structured understanding of the world, such as for automated
optimization of control of a system or process based on feedback or
feed forward to an operating model for the system or process. One
such machine learning technique for semantic and contextual
understandings, workflows, or other structured or semi-structured
understandings is disclosed in U.S. Pat. No. 8,200,775 to Moore,
issued 12 Jun. 2012, and hereby incorporated by reference as if
fully set forth herein. Machine learning may be used to improve the
foregoing, such as by adjusting one or more weights, structures,
rules, or the like (such as changing a function within a model)
based on feedback (such as regarding the success of a model in a
given situation) or based on iteration (such as in a recursive
process). Where sufficient understanding of the underlying
structure or behavior of a system is not known, insufficient data
is not available, or in other cases where preferred for various
reasons, machine learning may also be undertaken in the absence of
an underlying model; that is, input sources may be weighted,
structured, or the like within a machine learning facility without
regard to any a priori understanding of structure, and outcomes
(such as those based on measures of success at accomplishing
various desired objectives) can be serially fed to the machine
learning system to allow it to learn how to achieve the targeted
objectives. For example, the system may learn to recognize faults,
to recognize patterns, to develop models or functions, to develop
rules, to optimize performance, to minimize failure rates, to
optimize profits, to optimize resource utilization, to optimize
flow (such as flow of traffic), or to optimize many other
parameters that may be relevant to successful outcomes (such as
outcomes in a wide range of environments). Machine learning may use
genetic programming techniques, such as promoting or demoting one
or more input sources, structures, data types, objects, weights,
nodes, links, or other factors based on feedback (such that
successful elements emerge over a series of generations). For
example, alternative available sensor inputs for a data collection
system 102 may be arranged in alternative configurations and
permutations, such that the system may, using generic programming
techniques over a series of data collection events, determine what
permutations provide successful outcomes based on various
conditions (such as conditions of components of the platform 100,
conditions of the network 110, conditions of a data collection
system 102, conditions of an environment 104), or the like. In
embodiments, local machine learning may turn on or off one or more
sensors in a multi-sensor data collector 102 in permutations over
time, while tracking success outcomes such as contributing to
success in predicting a failure, contributing to a performance
indicator (such as efficiency, effectiveness, return on investment,
yield, or the like), contributing to optimization of one or more
parameters, identification of a pattern (such as relating to a
threat, a failure mode, a success mode, or the like) or the like.
For example, a system may learn what sets of sensors should be
turned on or off under given conditions to achieve the highest
value utilization of a data collector 102. In embodiments, similar
techniques may be used to handle optimization of transport of data
in the platform 100 (such as in the network 110) by using generic
programming or other machine learning techniques to learn to
configure network elements (such as configuring network transport
paths, configuring network coding types and architectures,
configuring network security elements), and the like.
[0229] In embodiments, the local data collection system 102 may
include a high-performance, multi-sensor data collector having a
number of novel features for collection and processing of analog
and other sensor data. In embodiments, a local data collection
system 102 may be deployed to the industrial facilities depicted in
FIG. 3. A local data collection system 102 may also be deployed
monitor other machines such as the machine 2300 in FIG. 9 and FIG.
10, the machines 2400, 2600, 2800, 2950, 3000 depicted in FIG. 12,
and the machines 3202, 3204 depicted in FIG. 13. The data
collection system 102 may have on-board intelligent systems 118
(such as for learning to optimize the configuration and operation
of the data collector, such as configuring permutations and
combinations of sensors based on contexts and conditions). In one
example, the data collection system 102 includes a crosspoint
switch 130 or other analog switch. Automated, intelligent
configuration of the local data collection system 102 may be based
on a variety of types of information, such as information from
various input sources, including those based on available power,
power requirements of sensors, the value of the data collected
(such as based on feedback information from other elements of the
platform 100), the relative value of information (such as values
based on the availability of other sources of the same or similar
information), power availability (such as for powering sensors),
network conditions, ambient conditions, operating states, operating
contexts, operating events, and many others.
[0230] FIG. 7 shows elements and sub-components of a data
collection and analysis system 1100 for sensor data (such as analog
sensor data) collected in industrial environments. As depicted in
FIG. 7, embodiments of the methods and systems disclosed herein may
include hardware that has several different modules starting with
the multiplexer ("MUX") main board 1104. In embodiments, there may
be a MUX option board 1108. The MUX 114 main board is where the
sensors connect to the system. These connections are on top to
enable ease of installation. Then there are numerous settings on
the underside of this board as well as on the Mux option board
1108, which attaches to the MUX main board 1104 via two headers one
at either end of the board. In embodiments, the Mux option board
has the male headers, which mesh together with the female header on
the main Mux board. This enables them to be stacked on top of each
other taking up less real estate.
[0231] In embodiments, the main Mux board and/or the MUX option
board then connects to the mother (e.g., with 4 simultaneous
channels) and daughter (e.g., with 4 additional channels for 8
total channels) analog boards 1110 via cables where some of the
signal conditioning (such as hardware integration) occurs. The
signals then move from the analog boards 1110 to an anti-aliasing
board (not shown) where some of the potential aliasing is removed.
The rest of the aliasing removal is done on the delta sigma board
1112. The delta sigma board 1112 provides more aliasing protection
along with other conditioning and digitizing of the signal. Next,
the data moves to the Jennic.TM. board 1114 for more digitizing as
well as communication to a computer via USB or Ethernet. In
embodiments, the Jennic.TM. board 1114 may be replaced with a pic
board 1118 for more advanced and efficient data collection as well
as communication. Once the data moves to the computer software
1102, the computer software 1102 can manipulate the data to show
trending, spectra, waveform, statistics, and analytics.
[0232] In embodiments, the system is meant to take in all types of
data from volts to 4-20 mA signals. In embodiments, open formats of
data storage and communication may be used. In some instances,
certain portions of the system may be proprietary especially some
of research and data associated with the analytics and reporting.
In embodiments, smart band analysis is a way to break data down
into easily analyzed parts that can be combined with other smart
bands to make new more simplified yet sophisticated analytics. In
embodiments, this unique information is taken and graphics are used
to depict the conditions because picture depictions are more
helpful to the user. In embodiments, complicated programs and user
interfaces are simplified so that any user can manipulate the data
like an expert.
[0233] In embodiments, the system in essence, works in a big loop.
The system starts in software with a general user interface ("GUI")
1124. In embodiments, rapid route creation may take advantage of
hierarchical templates. In embodiments, a GUI is created so any
general user can populate the information itself with simple
templates. Once the templates are created the user can copy and
paste whatever the user needs. In addition, users can develop their
own templates for future ease of use and to institutionalize the
knowledge. When the user has entered all of the user's information
and connected all of the user's sensors, the user can then start
the system acquiring data.
[0234] Embodiments of the methods and systems disclosed herein may
include unique electrostatic protection for trigger and vibration
inputs. In many critical industrial environments where large
electrostatic forces, which can harm electrical equipment, may
build up, for example rotating machinery or low-speed balancing
using large belts, proper transducer and trigger input protection
is required. In embodiments, a low-cost but efficient method is
described for such protection without the need for external
supplemental devices.
[0235] Typically, vibration data collectors are not designed to
handle large input voltages due to the expense and the fact that,
more often than not, it is not needed. A need exists for these data
collectors to acquire many varied types of RPM data as technology
improves and monitoring costs plummet. In embodiments, a method is
using the already established OptoMOS.TM. technology which permits
the switching up front of high voltage signals rather than using
more conventional reed-relay approaches. Many historic concerns
regarding non-linear zero crossing or other non-linear solid-state
behaviors have been eliminated with regard to the passing through
of weakly buffered analog signals. In addition, in embodiments,
printed circuit board routing topologies place all of the
individual channel input circuitry as close to the input connector
as possible. In embodiments, a unique electrostatic protection for
trigger and vibration inputs may be placed upfront on the Mux and
DAQ hardware in order to dissipate the built up electric charge as
the signal passed from the sensor to the hardware. In embodiments,
the Mux and analog board may support high-amperage input using a
design topology comprising wider traces and solid state relays for
upfront circuitry.
[0236] In some systems multiplexers are afterthoughts and the
quality of the signal coming from the multiplexer is not
considered. As a result of a poor quality multiplexer, the quality
of the signal can drop as much as 30 dB or more. Thus, substantial
signal quality may be lost using a 24-bit DAQ that has a signal to
noise ratio of 110 dB and if the signal to noise ratio drops to 80
dB in the Mux, it may not be much better than a 16-bit system from
20 years ago. In embodiments of this system, an important part at
the front of the Mux is upfront signal conditioning on Mux for
improved signal-to-noise ratio. Embodiments may perform signal
conditioning (such as range/gain control, integration, filtering,
etc.) on vibration as well as other signal inputs up front before
Mux switching to achieve the highest signal-to-noise ratio.
[0237] In embodiments, in addition to providing a better signal,
the multiplexer may provide a continuous monitor alarming feature.
Truly continuous systems monitor every sensor all the time but tend
to be expensive. Typical multiplexer systems only monitor a set
number of channels at one time and switch from bank to bank of a
larger set of sensors. As a result, the sensors not being currently
collected are not being monitored; if a level increases the user
may never know. In embodiments, a multiplexer may have a continuous
monitor alarming feature by placing circuitry on the multiplexer
that can measure input channel levels against known alarm
conditions even when the data acquisition ("DAQ") is not monitoring
the input. In embodiments, continuous monitoring Mux bypass offers
a mechanism whereby channels not being currently sampled by the Mux
system may be continuously monitored for significant alarm
conditions via a number of trigger conditions using filtered
peak-hold circuits or functionally similar that are in turn passed
on to the monitoring system in an expedient manner using hardware
interrupts or other means. This, in essence, makes the system
continuously monitoring, although without the ability to instantly
capture data on the problem like a true continuous system. In
embodiments, coupling this capability to alarm with adaptive
scheduling techniques for continuous monitoring and the continuous
monitoring system's software adapting and adjusting the data
collection sequence based on statistics, analytics, data alarms and
dynamic analysis may allow the system to quickly collect dynamic
spectral data on the alarming sensor very soon after the alarm
sounds.
[0238] Another restriction of typical multiplexers is that they may
have a limited number of channels. In embodiments, use of
distributed complex programmable logic device ("CPLD") chips with
dedicated bus for logic control of multiple Mux and data
acquisition sections enables a CPLD to control multiple mux and
DAQs so that there is no limit to the number of channels a system
can handle. Interfacing to multiple types of predictive maintenance
and vibration transducers requires a great deal of switching. This
includes AC/DC coupling, 4-20 interfacing, integrated electronic
piezoelectric transducer, channel power-down (for conserving op-amp
power), single-ended or differential grounding options, and so on.
Also required is the control of digital pots for range and gain
control, switches for hardware integration, AA filtering and
triggering. This logic can be performed by a series of CPLD chips
strategically located for the tasks they control. A single giant
CPLD requires long circuit routes with a great deal of density at
the single giant CPLD. In embodiments, distributed CPLDs not only
address these concerns but offer a great deal of flexibility. A bus
is created where each CPLD that has a fixed assignment has its own
unique device address. In embodiments, multiplexers and DAQs can
stack together offering additional input and output channels to the
system. For multiple boards (e.g., for multiple Mux boards),
jumpers are provided for setting multiple addresses. In another
example, three bits permit up to 8 boards that are jumper
configurable. In embodiments, a bus protocol is defined such that
each CPLD on the bus can either be addressed individually or as a
group.
[0239] Typical multiplexers may be limited to collecting only
sensors in the same bank. For detailed analysis, this may be
limiting as there is tremendous value in being able to
simultaneously review data from sensors on the same machine.
Current systems using conventional fixed bank multiplexers can only
compare a limited number of channels (based on the number of
channels per bank) that were assigned to a particular group at the
time of installation. The only way to provide some flexibility is
to either overlap channels or incorporate lots of redundancy in the
system both of which can add considerable expense (in some cases an
exponential increase in cost versus flexibility). The simplest Mux
design selects one of many inputs and routes it into a single
output line. A banked design would consist of a group of these
simple building blocks, each handling a fixed group of inputs and
routing to its respective output. Typically, the inputs are not
overlapping so that the input of one Mux grouping cannot be routed
into another. Unlike conventional Mux chips which typically switch
a fixed group or banks of a fixed selection of channels into a
single output (e.g., in groups of 2, 4, 8, etc.), a cross point Mux
allows the user to assign any input to any output. Previously,
crosspoint multiplexers were used for specialized purposes such as
RGB digital video applications and were as a practical matter too
noisy for analog applications such as vibration analysis; however
more recent advances in the technology now make it feasible.
Another advantage of the crosspoint Mux is the ability to disable
outputs by putting them into a high impedance state. This is ideal
for an output bus so that multiple Mux cards may be stacked, and
their output buses joined together without the need for bus
switches.
[0240] In embodiments, this may be addressed by use of an analog
crosspoint switch for collecting variable groups of vibration input
channels and providing a matrix circuit so the system may access
any set of eight channels from the total number of input
sensors.
[0241] In embodiments, the ability to control multiple multiplexers
with use of distributed CPLD chips with dedicated bus for logic
control of multiple Mux and data acquisition sections is enhanced
with a hierarchical multiplexer which allows for multiple DAQ to
collect data from multiple multiplexers. A hierarchical Mux may
allow modularly output of more channels, such as 16, 24 or more to
multiple of eight channel card sets. In embodiments, this allows
for faster data collection as well as more channels of simultaneous
data collection for more complex analysis. In embodiments, the Mux
may be configured slightly to make it portable and use data
acquisition parking features, which turns SV3X DAQ into a protected
system embodiment.
[0242] In embodiments, once the signals leave the multiplexer and
hierarchical Mux they move to the analog board where there are
other enhancements. In embodiments, power saving techniques may be
used such as: power-down of analog channels when not in use;
powering down of component boards; power-down of analog signal
processing op-amps for non-selected channels; powering down
channels on the mother and the daughter analog boards. The ability
to power down component boards and other hardware by the low-level
firmware for the DAQ system makes high-level application control
with respect to power-saving capabilities relatively easy. Explicit
control of the hardware is always possible but not required by
default. In embodiments, this power saving benefit may be of value
to a protected system, especially if it is battery operated or
solar powered.
[0243] In embodiments, in order to maximize the signal to noise
ratio and provide the best data, a peak-detector for auto-scaling
routed into a separate A/D will provide the system the highest peak
in each set of data so it can rapidly scale the data to that peak.
For vibration analysis purposes, the built-in A/D converters in
many microprocessors may be inadequate with regards to number of
bits, number of channels or sampling frequency versus not slowing
the microprocessor down significantly. Despite these limitations,
it is useful to use them for purposes of auto-scaling. In
embodiments, a separate A/D may be used that has reduced
functionality and is cheaper. For each channel of input, after the
signal is buffered (usually with the appropriate coupling: AC or
DC) but before it is signal conditioned, the signal is fed directly
into the microprocessor or low-cost A/D. Unlike the conditioned
signal for which range, gain and filter switches are thrown, no
switches are varied. This permits the simultaneous sampling of the
auto-scaling data while the input data is signal conditioned, fed
into a more robust external A/D, and directed into on-board memory
using direct memory access (DMA) methods where memory is accessed
without requiring a CPU. This significantly simplifies the
auto-scaling process by not having to throw switches and then allow
for settling time, which greatly slows down the auto-scaling
process. Furthermore, the data may be collected simultaneously,
which assures the best signal-to-noise ratio. The reduced number of
bits and other features is usually more than adequate for
auto-scaling purposes. In embodiments, improved integration using
both analog and digital methods create an innovative hybrid
integration which also improves or maintains the highest possible
signal to noise ratio.
[0244] In embodiments, a section of the analog board may allow
routing of a trigger channel, either raw or buffered, into other
analog channels. This may allow a user to route the trigger to any
of the channels for analysis and trouble shooting. Systems may have
trigger channels for the purposes of determining relative phase
between various input data sets or for acquiring significant data
without the needless repetition of unwanted input. In embodiments,
digitally controlled relays may be used to switch either the raw or
buffered trigger signal into one of the input channels. It may be
desirable to examine the quality of the triggering pulse because it
may be corrupted for a variety of reasons including inadequate
placement of the trigger sensor, wiring issues, faulty setup issues
such as a dirty piece of reflective tape if using an optical
sensor, and so on. The ability to look at either the raw or
buffered signal may offer an excellent diagnostic or debugging
vehicle. It also can offer some improved phase analysis capability
by making use of the recorded data signal for various signal
processing techniques such as variable speed filtering
algorithms.
[0245] In embodiments, once the signals leave the analog board, the
signals move into the delta-sigma board where precise voltage
reference for A/D zero reference offers more accurate direct
current sensor data. The delta sigma's high speeds also provide for
using higher input oversampling for delta-sigma A/D for lower
sampling rate outputs to minimize antialiasing filter requirements.
Lower oversampling rates can be used for higher sampling rates. For
example, a 3rd order AA filter set for the lowest sampling
requirement for 256 Hz (Fmax of 100 Hz) is then adequate for Fmax
ranges of 200 and 500 Hz. Another higher-cutoff AA filter can then
be used for Fmax ranges from 1 kHz and higher (with a secondary
filter kicking in at 2.56.times. the highest sampling rate of 128
kHz). In embodiments, a CPLD may be used as a clock-divider for a
delta-sigma A/D to achieve lower sampling rates without the need
for digital resampling. In embodiments, a high-frequency crystal
reference can be divided down to lower frequencies by employing a
CPLD as a programmable clock divider. The accuracy of the divided
down lower frequencies is even more accurate than the original
source relative to their longer time periods. This also minimizes
or removes the need for resampling processing by the delta-sigma
A/D.
[0246] In embodiments, the data then moves from the delta-sigma
board to the Jennic.TM. board where phase relative to input and
trigger channels using on-board timers may be digitally derived. In
embodiments, the Jennic.TM. board also has the ability to store
calibration data and system maintenance repair history data in an
on-board card set. In embodiments, the Jennic.TM. board will enable
acquiring long blocks of data at high-sampling rate as opposed to
multiple sets of data taken at different sampling rates so it can
stream data and acquire long blocks of data for advanced analysis
in the future.
[0247] In embodiments, after the signal moves through the
Jennic.TM. board it may then be transmitted to the computer. In
embodiments, the computer software will be used to add intelligence
to the system starting with an expert system GUI. The GUI will
offer a graphical expert system with simplified user interface for
defining smart bands and diagnoses which facilitate anyone to
develop complex analytics. In embodiments, this user interface may
revolve around smart bands, which are a simplified approach to
complex yet flexible analytics for the general user. In
embodiments, the smart bands may pair with a self-learning neural
network for an even more advanced analytical approach. In
embodiments, this system may use the machine's hierarchy for
additional analytical insight. One critical part of predictive
maintenance is the ability to learn from known information during
repairs or inspections. In embodiments, graphical approaches for
back calculations may improve the smart bands and correlations
based on a known fault or problem.
[0248] In embodiments, there is a smart route which adapts which
sensors it collects simultaneously in order to gain additional
correlative intelligence. In embodiments, smart operational data
store ("ODS") allows the system to elect to gather data to perform
operational deflection shape analysis in order to further examine
the machinery condition. In embodiments, adaptive scheduling
techniques allow the system to change the scheduled data collected
for full spectral analysis across a number (e.g., eight), of
correlative channels. In embodiments, the system may provide data
to enable extended statistics capabilities for continuous
monitoring as well as ambient local vibration for analysis that
combines ambient temperature and local temperature and vibration
levels changes for identifying machinery issues.
[0249] In embodiments, a data acquisition device may be controlled
by a personal computer (PC) to implement the desired data
acquisition commands. In embodiments, the DAQ box may be
self-sufficient. and can acquire, process, analyze and monitor
independent of external PC control. Embodiments may include secure
digital (SD) card storage. In embodiments, significant additional
storage capability may be provided by utilizing an SD card. This
may prove critical for monitoring applications where critical data
may be stored permanently. Also, if a power failure should occur,
the most recent data may be stored despite the fact that it was not
off-loaded to another system.
[0250] A current trend has been to make DAQ systems as
communicative as possible with the outside world usually in the
form of networks including wireless. In the past it was common to
use a dedicated bus to control a DAQ system with either a
microprocessor or microcontroller/microprocessor paired with a PC.
In embodiments, a DAQ system may comprise one or more
microprocessor/microcontrollers, specialized
microcontrollers/microprocessors, or dedicated processors focused
primarily on the communication aspects with the outside world.
These include USB, Ethernet and wireless with the ability to
provide an IP address or addresses in order to host a webpage. All
communications with the outside world are then accomplished using a
simple text based menu. The usual array of commands (in practice
more than a hundred) such as InitializeCard, AcquireData,
StopAcquisition, RetrieveCalibration Info, and so on, would be
provided.
[0251] In embodiments, intense signal processing activities
including resampling, weighting, filtering, and spectrum processing
may be performed by dedicated processors such as field-programmable
gate array ("FPGAs"), digital signal processor ("DSP"),
microprocessors, micro-controllers, or a combination thereof. In
embodiments, this subsystem may communicate via a specialized
hardware bus with the communication processing section. It will be
facilitated with dual-port memory, semaphore logic, and so on. This
embodiment will not only provide a marked improvement in efficiency
but can significantly improve the processing capability, including
the streaming of the data as well other high-end analytical
techniques. This negates the need for constantly interrupting the
main processes which include the control of the signal conditioning
circuits, triggering, raw data acquisition using the A/D, directing
the A/D output to the appropriate on-board memory and processing
that data.
[0252] Embodiments may include sensor overload identification. A
need exists for monitoring systems to identify when the sensor is
overloading. There may be situations involving high-frequency
inputs that will saturate a standard 100 mv/g sensor (which is most
commonly used in the industry) and having the ability to sense the
overload improves data quality for better analysis. A monitoring
system may identify when their system is overloading, but in
embodiments, the system may look at the voltage of the sensor to
determine if the overload is from the sensor, enabling the user to
get another sensor better suited to the situation, or gather the
data again.
[0253] Embodiments may include radio frequency identification
("RFID") and an inclinometer or accelerometer on a sensor so the
sensor can indicate what machine/bearing it is attached to and what
direction such that the software can automatically store the data
without the user input. In embodiments, users could put the system
on any machine or machines and the system would automatically set
itself up and be ready for data collection in seconds.
[0254] Embodiments may include ultrasonic online monitoring by
placing ultrasonic sensors inside transformers, motor control
centers, breakers and the like and monitoring, via a sound
spectrum, continuously looking for patterns that identify arcing,
corona and other electrical issues indicating a break down or
issue. Embodiments may include providing continuous ultrasonic
monitoring of rotating elements and bearings of an energy
production facility. In embodiments, an analysis engine may be used
in ultrasonic online monitoring as well as identifying other faults
by combining the ultrasonic data with other parameters such as
vibration, temperature, pressure, heat flux, magnetic fields,
electrical fields, currents, voltage, capacitance, inductance, and
combinations (e.g., simple ratios) of the same, among many
others.
[0255] Embodiments of the methods and systems disclosed herein may
include use of an analog crosspoint switch for collecting variable
groups of vibration input channels. For vibration analysis, it is
useful to obtain multiple channels simultaneously from vibration
transducers mounted on different parts of a machine (or machines)
in multiple directions. By obtaining the readings at the same time,
for example, the relative phases of the inputs may be compared for
the purpose of diagnosing various mechanical faults. Other types of
cross channel analyses such as cross-correlation, transfer
functions, Operating Deflection Shape ("ODS") may also be
performed.
[0256] Embodiments of the methods and systems disclosed herein may
include precise voltage reference for A/D zero reference. Some A/D
chips provide their own internal zero voltage reference to be used
as a mid-scale value for external signal conditioning circuitry to
ensure that both the A/D and external op-amps use the same
reference. Although this sounds reasonable in principle, there are
practical complications. In many cases these references are
inherently based on a supply voltage using a resistor-divider. For
many current systems, especially those whose power is derived from
a PC via USB or similar bus, this provides for an unreliable
reference, as the supply voltage will often vary quite
significantly with load. This is especially true for delta-sigma
A/D chips which necessitate increased signal processing. Although
the offsets may drift together with load, a problem arises if one
wants to calibrate the readings digitally. It is typical to modify
the voltage offset expressed as counts coming from the A/D
digitally to compensate for the DC drift. However, for this case,
if the proper calibration offset is determined for one set of
loading conditions, they will not apply for other conditions. An
absolute DC offset expressed in counts will no longer be
applicable. As a result, it becomes necessary to calibrate for all
loading conditions which becomes complex, unreliable, and
ultimately unmanageable. In embodiments, an external voltage
reference is used which is simply independent of the supply voltage
to use as the zero offset.
[0257] In embodiments, the system provides a phase-lock-loop band
pass tracking filter method for obtaining slow-speed RPMs and phase
for balancing purposes to remotely balance slow speed machinery,
such as in paper mills, as well as offering additional analysis
from its data. For balancing purposes, it is sometimes necessary to
balance at very slow speeds. A typical tracking filter may be
constructed based on a phase-lock loop or PLL design; however,
stability and speed range are overriding concerns. In embodiments,
a number of digitally controlled switches are used for selecting
the appropriate RC and damping constants. The switching can be done
all automatically after measuring the frequency of the incoming
tach signal. Embodiments of the methods and systems disclosed
herein may include digital derivation of phase relative to input
and trigger channels using on-board timers. In embodiments, digital
phase derivation uses digital timers to ascertain an exact delay
from a trigger event to the precise start of data acquisition. This
delay, or offset, then, is further refined using interpolation
methods to obtain an even more precise offset which is then applied
to the analytically determined phase of the acquired data such that
the phase is "in essence" an absolute phase with precise mechanical
meaning useful for among other things, one-shot balancing,
alignment analysis, and so on.
[0258] Embodiments of the methods and systems disclosed herein may
include signal processing firmware/hardware. In embodiments, long
blocks of data may be acquired at high-sampling rate as opposed to
multiple sets of data taken at different sampling rates. Typically,
in modern route collection for vibration analysis, it is customary
to collect data at a fixed sampling rate with a specified data
length. The sampling rate and data length may vary from route point
to point based on the specific mechanical analysis requirements at
hand. For example, a motor may require a relatively low sampling
rate with high resolution to distinguish running speed harmonics
from line frequency harmonics. The practical trade-off here though
is that it takes more collection time to achieve this improved
resolution. In contrast, some high-speed compressors or gear sets
require much higher sampling rates to measure the amplitudes of
relatively higher frequency data although the precise resolution
may not be as necessary. Ideally, however, it would be better to
collect a very long sample length of data at a very high-sampling
rate. When digital acquisition devices were first popularized in
the early 1980's, the A/D sampling, digital storage, and
computational abilities were not close to what they are today, so
compromises were made between the time required for data collection
and the desired resolution and accuracy. It was because of this
limitation that some analysts in the field even refused to give up
their analog tape recording systems, which did not suffer as much
from these same digitizing drawbacks. A few hybrid systems were
employed that would digitize the play back of the recorded analog
data at multiple sampling rates and lengths desired, though these
systems were admittedly less automated. The more common approach,
as mentioned earlier, is to balance data collection time with
analysis capability and digitally acquire the data blocks at
multiple sampling rates and sampling lengths and digitally store
these blocks separately. In embodiments, a long data length of data
can be collected at the highest practical sampling rate (e.g.,
102.4 kHz; corresponding to a 40 kHz Fmax) and stored. This long
block of data can be acquired in the same amount of time as the
shorter length of the lower sampling rates utilized by a priori
methods so that there is no effective delay added to the sampling
at the measurement point, always a concern in route collection. In
embodiments, analog tape recording of data is digitally simulated
with such a precision that it can be in effect considered
continuous or "analog" for many purposes, including for purposes of
embodiments of the present disclosure, except where context
indicates otherwise.
[0259] Embodiments of the methods and systems disclosed herein may
include storage of calibration data and maintenance history
on-board card sets. Many data acquisition devices which rely on
interfacing to a PC to function store their calibration
coefficients on the PC. This is especially true for complex data
acquisition devices whose signal paths are many and therefore whose
calibration tables can be quite large. In embodiments, calibration
coefficients are stored in flash memory which will remember this
data or any other significant information for that matter, for all
practical purposes, permanently. This information may include
nameplate information such as serial numbers of individual
components, firmware or software version numbers, maintenance
history, and the calibration tables. In embodiments, no matter
which computer the box is ultimately connected to, the DAQ box
remains calibrated and continues to hold all of this critical
information. The PC or external device may poll for this
information at any time for implantation or information exchange
purposes.
[0260] Embodiments of the methods and systems disclosed herein may
include rapid route creation taking advantage of hierarchical
templates. In the field of vibration monitoring, as well as
parametric monitoring in general, it is necessary to establish in a
database or functional equivalent the existence of data monitoring
points. These points are associated a variety of attributes
including the following categories: transducer attributes, data
collection settings, machinery parameters and operating parameters.
The transducer attributes would include probe type, probe mounting
type and probe mounting direction or axis orientation. Data
collection attributes associated with the measurement would involve
a sampling rate, data length, integrated electronic piezoelectric
probe power and coupling requirements, hardware integration
requirements, 4-20 or voltage interfacing, range and gain settings
(if applicable), filter requirements, and so on. Machinery
parametric requirements relative to the specific point would
include such items as operating speed, bearing type, bearing
parametric data which for a rolling element bearing includes the
pitch diameter, number of balls, inner race, and outer-race
diameters. For a tilting pad bearing, this would include the number
of pads and so on. For measurement points on a piece of equipment
such as a gearbox, needed parameters would include, for example,
the number of gear teeth on each of the gears. For induction
motors, it would include the number of rotor bars and poles; for
compressors, the number of blades and/or vanes; for fans, the
number of blades. For belt/pulley systems, the number of belts as
well as the relevant belt-passing frequencies may be calculated
from the dimensions of the pulleys and pulley center-to-center
distance. For measurements near couplings, the coupling type and
number of teeth in a geared coupling may be necessary, and so on.
Operating parametric data would include operating load, which may
be expressed in megawatts, flow (either air or fluid), percentage,
horsepower, feet-per-minute, and so on. Operating temperatures both
ambient and operational, pressures, humidity, and so on, may also
be relevant. As can be seen, the setup information required for an
individual measurement point can be quite large. It is also crucial
to performing any legitimate analysis of the data. Machinery,
equipment, and bearing specific information are essential for
identifying fault frequencies as well as anticipating the various
kinds of specific faults to be expected. The transducer attributes
as well as data collection parameters are vital for properly
interpreting the data along with providing limits for the type of
analytical techniques suitable. The traditional means of entering
this data has been manual and quite tedious, usually at the lowest
hierarchical level (for example, at the bearing level with regards
to machinery parameters), and at the transducer level for data
collection setup information. It cannot be stressed enough,
however, the importance of the hierarchical relationships necessary
to organize data--both for analytical and interpretive purposes as
well as the storage and movement of data. Here, we are focusing
primarily on the storage and movement of data. By its nature, the
aforementioned setup information is extremely redundant at the
level of the lowest hierarchies; however, because of its strong
hierarchical nature, it can be stored quite efficiently in that
form. In embodiments, hierarchical nature can be utilized when
copying data in the form of templates. As an example, hierarchical
storage structure suitable for many purposes is defined from
general to specific of company, plant or site, unit or process,
machine, equipment, shaft element, bearing, and transducer. It is
much easier to copy data associated with a particular machine,
piece of equipment, shaft element or bearing than it is to copy
only at the lowest transducer level. In embodiments, the system not
only stores data in this hierarchical fashion, but robustly
supports the rapid copying of data using these hierarchical
templates. Similarity of elements at specific hierarchical levels
lends itself to effective data storage in hierarchical format. For
example, so many machines have common elements such as motors,
gearboxes, compressors, belts, fans, and so on. More specifically,
many motors can be easily classified as induction, DC, fixed or
variable speed. Many gearboxes can be grouped into commonly
occurring groupings such as input/output, input pinion/intermediate
pinion/output pinion, 4-posters, and so on. Within a plant or
company, there are many similar types of equipment purchased and
standardized on for both cost and maintenance reasons. This results
in an enormous overlapping of similar types of equipment and, as a
result, offers a great opportunity for taking advantage of a
hierarchical template approach.
[0261] Embodiments of the methods and systems disclosed herein may
include smart bands. Smart bands refer to any processed signal
characteristics derived from any dynamic input or group of inputs
for the purposes of analyzing the data and achieving the correct
diagnoses. Furthermore, smart bands may even include mini or
relatively simple diagnoses for the purposes of achieving a more
robust and complex one. Historically, in the field of mechanical
vibration analysis, Alarm Bands have been used to define spectral
frequency bands of interest for the purposes of analyzing and/or
trending significant vibration patterns. The Alarm Band typically
consists of a spectral (amplitude plotted against frequency) region
defined between a low and high frequency border. The amplitude
between these borders is summed in the same manner for which an
overall amplitude is calculated. A Smart Band is more flexible in
that it not only refers to a specific frequency band but can also
refer to a group of spectral peaks such as the harmonics of a
single peak, a true-peak level or crest factor derived from a time
waveform, an overall derived from a vibration envelope spectrum or
other specialized signal analysis technique or a logical
combination (AND, OR, XOR, etc.) of these signal attributes. In
addition, a myriad assortment of other parametric data, including
system load, motor voltage and phase information, bearing
temperature, flow rates, and the like, can likewise be used as the
basis for forming additional smart bands. In embodiments, Smart
Band symptoms may be used as building blocks for an expert system
whose engine would utilize these inputs to derive diagnoses. Some
of these mini-diagnoses may then in turn be used as Smart-Band
symptoms (smart bands can include even diagnoses) for more
generalized diagnoses.
[0262] Embodiments of the methods and systems disclosed herein may
include a neural net expert system using smart bands. Typical
vibration analysis engines are rule-based (i.e., they use a list of
expert rules which, when met, trigger specific diagnoses). In
contrast, a neural approach utilizes the weighted triggering of
multiple input stimuli into smaller analytical engines or neurons
which in turn feed a simplified weighted output to other neurons.
The output of these neurons can be also classified as smart bands
which in turn feed other neurons. This produces a more layered
approach to expert diagnosing as opposed to the one-shot approach
of a rule-based system. In embodiments, the expert system utilizes
this neural approach using smart bands; however, it does not
preclude rule-based diagnoses being reclassified as smart bands as
further stimuli to be utilized by the expert system. From this
point-of-view, it can be overviewed as a hybrid approach, although
at the highest level it is essentially neural.
[0263] Embodiments of the methods and systems disclosed herein may
include use of database hierarchy in analysis smart band symptoms
and diagnoses may be assigned to various hierarchical database
levels. For example, a smart band may be called "Looseness" at the
bearing level, trigger "Looseness" at the equipment level, and
trigger "Looseness" at the machine level. Another example would be
having a smart band diagnosis called "Horizontal Plane Phase Flip"
across a coupling and generate a smart band diagnosis of "Vertical
Coupling Misalignment" at the machine level.
[0264] Embodiments of the methods and systems disclosed herein may
include expert system GUIs. In embodiments, the system undertakes a
graphical approach to defining smart bands and diagnoses for the
expert system. The entry of symptoms, rules, or more generally
smart bands for creating a particular machine diagnosis, may be
tedious and time consuming. One means of making the process more
expedient and efficient is to provide a graphical means by use of
wiring. The proposed graphical interface consists of four major
components: a symptom parts bin, diagnoses bin, tools bin, and
graphical wiring area ("GWA"). In embodiments, a symptom parts bin
includes various spectral, waveform, envelope and any type of
signal processing characteristic or grouping of characteristics
such as a spectral peak, spectral harmonic, waveform true-peak,
waveform crest-factor, spectral alarm band, and so on. Each part
may be assigned additional properties. For example, a spectral peak
part may be assigned a frequency or order (multiple) of running
speed. Some parts may be pre-defined or user defined such as a
1.times., 2.times., 3.times. running speed, 1.times., 2.times.,
3.times. gear mesh, 1.times., 2.times., 3.times. blade pass, number
of motor rotor bars.times.running speed, and so on.
[0265] In embodiments, the diagnoses bin includes various
pre-defined as well as user-defined diagnoses such as misalignment,
imbalance, looseness, bearing faults, and so on. Like parts,
diagnoses may also be used as parts for the purposes of building
more complex diagnoses. In embodiments, the tools bin includes
logical operations such as AND, OR, XOR, etc. or other ways of
combining the various parts listed above such as Find Max, Find
Min, Interpolate, Average, other Statistical Operations, etc. In
embodiments, a graphical wiring area includes parts from the parts
bin or diagnoses from the diagnoses bin and may be combined using
tools to create diagnoses. The various parts, tools and diagnoses
will be represented with icons which are simply graphically wired
together in the desired manner.
[0266] Embodiments of the methods and systems disclosed herein may
include a graphical approach for back-calculation definition. In
embodiments, the expert system also provides the opportunity for
the system to learn. If one already knows that a unique set of
stimuli or smart bands corresponds to a specific fault or
diagnosis, then it is possible to back-calculate a set of
coefficients that when applied to a future set of similar stimuli
would arrive at the same diagnosis. In embodiments, if there are
multiple sets of data, a best-fit approach may be used. Unlike the
smart band GUI, this embodiment will self-generate a wiring
diagram. In embodiments, the user may tailor the back-propagation
approach settings and use a database browser to match specific sets
of data with the desired diagnoses. In embodiments, the desired
diagnoses may be created or custom tailored with a smart band GUI.
In embodiments, after that, a user may press the GENERATE button
and a dynamic wiring of the symptom-to-diagnosis may appear on the
screen as it works through the algorithms to achieve the best fit.
In embodiments, when complete, a variety of statistics are
presented which detail how well the mapping process proceeded. In
some cases, no mapping may be achieved if, for example, the input
data was all zero or the wrong data (mistakenly assigned) and so
on. Embodiments of the methods and systems disclosed herein may
include bearing analysis methods. In embodiments, bearing analysis
methods may be used in conjunction with a computer aided design
("CAD"), predictive deconvolution, minimum variance distortionless
response ("MVDR") and spectrum sum-of-harmonics.
[0267] In recent years, there has been a strong drive to save power
which has resulted in an influx of variable frequency drives and
variable speed machinery. In embodiments, a bearing analysis method
is provided. In embodiments, torsional vibration detection and
analysis is provided utilizing transitory signal analysis to
provide an advanced torsional vibration analysis for a more
comprehensive way to diagnose machinery where torsional forces are
relevant (such as machinery with rotating components). Due
primarily to the decrease in cost of motor speed control systems,
as well as the increased cost and consciousness of energy-usage, it
has become more economically justifiable to take advantage of the
potentially vast energy savings of load control. Unfortunately, one
frequently overlooked design aspect of this issue is that of
vibration. When a machine is designed to run at only one speed, it
is far easier to design the physical structure accordingly so as to
avoid mechanical resonances both structural and torsional, each of
which can dramatically shorten the mechanical health of a machine.
This would include such structural characteristics as the types of
materials to use, their weight, stiffening member requirements and
placement, bearing types, bearing location, base support
constraints, etc. Even with machines running at one speed,
designing a structure so as to minimize vibration can prove a
daunting task, potentially requiring computer modeling,
finite-element analysis, and field testing. By throwing variable
speeds into the mix, in many cases, it becomes impossible to design
for all desirable speeds. The problem then becomes one of
minimization, e.g., by speed avoidance. This is why many modern
motor controllers are typically programmed to skip or quickly pass
through specific speed ranges or bands. Embodiments may include
identifying speed ranges in a vibration monitoring system.
Non-torsional, structural resonances are typically fairly easy to
detect using conventional vibration analysis techniques. However,
this is not the case for torsion. One special area of current
interest is the increased incidence of torsional resonance
problems, apparently due to the increased torsional stresses of
speed change as well as the operation of equipment at torsional
resonance speeds. Unlike non-torsional structural resonances which
generally manifest their effect with dramatically increased casing
or external vibration, torsional resonances generally show no such
effect. In the case of a shaft torsional resonance, the twisting
motion induced by the resonance may only be discernible by looking
for speed and/or phase changes. The current standard methodology
for analyzing torsional vibration involves the use of specialized
instrumentation. Methods and systems disclosed herein allow
analysis of torsional vibration without such specialized
instrumentation. This may consist of shutting the machine down and
employing the use of strain gauges and/or other special fixturing
such as speed encoder plates and/or gears. Friction wheels are
another alternative, but they typically require manual
implementation and a specialized analyst. In general, these
techniques can be prohibitively expensive and/or inconvenient. An
increasing prevalence of continuous vibration monitoring systems
due to decreasing costs and increasing convenience (e.g., remote
access) exists. In embodiments, there is an ability to discern
torsional speed and/or phase variations with just the vibration
signal. In embodiments, transient analysis techniques may be
utilized to distinguish torsionally induced vibrations from mere
speed changes due to process control. In embodiments, factors for
discernment might focus on one or more of the following aspects:
the rate of speed change due to variable speed motor control would
be relatively slow, sustained and deliberate; torsional speed
changes would tend to be short, impulsive and not sustained;
torsional speed changes would tend to be oscillatory, most likely
decaying exponentially, process speed changes would not; and
smaller speed changes associated with torsion relative to the
shaft's rotational speed which suggest that monitoring phase
behavior would show the quick or transient speed bursts in contrast
to the slow phase changes historically associated with ramping a
machine's speed up or down (as typified with Bode or Nyquist
plots).
[0268] Embodiments of the methods and systems disclosed herein may
include improved integration using both analog and digital methods.
When a signal is digitally integrated using software, essentially
the spectral low-end frequency data has its amplitude multiplied by
a function which quickly blows up as it approaches zero and creates
what is known in the industry as a "ski-slope" effect. The
amplitude of the ski-slope is essentially the noise floor of the
instrument. The simple remedy for this is the traditional hardware
integrator, which can perform at signal-to-noise ratios much
greater than that of an already digitized signal. It can also limit
the amplification factor to a reasonable level so that
multiplication by very large numbers is essentially prohibited.
However, at high frequencies where the frequency becomes large, the
original amplitude which may be well above the noise floor is
multiplied by a very small number (1/f) that plunges it well below
the noise floor. The hardware integrator has a fixed noise floor
that although low floor does not scale down with the now lower
amplitude high-frequency data. In contrast, the same digital
multiplication of a digitized high-frequency signal also scales
down the noise floor proportionally. In embodiments, hardware
integration may be used below the point of unity gain where (at a
value usually determined by units and/or desired signal to noise
ratio based on gain) and software integration may be used above the
value of unity gain to produce an ideal result. In embodiments,
this integration is performed in the frequency domain. In
embodiments, the resulting hybrid data can then be transformed back
into a waveform which should be far superior in signal-to-noise
ratio when compared to either hardware integrated or software
integrated data. In embodiments, the strengths of hardware
integration are used in conjunction with those of digital software
integration to achieve the maximum signal-to-noise ratio. In
embodiments, the first order gradual hardware integrator high pass
filter along with curve fitting allow some relatively low frequency
data to get through while reducing or eliminating the noise,
allowing very useful analytical data that steep filters kill to be
salvaged.
[0269] Embodiments of the methods and systems disclosed herein may
include adaptive scheduling techniques for continuous monitoring.
Continuous monitoring is often performed with an up-front Mux whose
purpose it is to select a few channels of data among many to feed
the hardware signal processing, A/D, and processing components of a
DAQ system. This is done primarily out of practical cost
considerations. The tradeoff is that all of the points are not
monitored continuously (although they may be monitored to a lesser
extent via alternative hardware methods). In embodiments, multiple
scheduling levels are provided. In embodiments, at the lowest
level, which is continuous for the most part, all of the
measurement points will be cycled through in round-robin fashion.
For example, if it takes 30 seconds to acquire and process a
measurement point and there are 30 points, then each point is
serviced once every 15 minutes; however, if a point should alarm by
whatever criteria the user selects, its priority level can be
increased so that it is serviced more often. As there can be
multiple grades of severity for each alarm, so can there me
multiple levels of priority with regards to monitoring. In
embodiments, more severe alarms will be monitored more frequently.
In embodiments, a number of additional high-level signal processing
techniques can be applied at less frequent intervals. Embodiments
may take advantage of the increased processing power of a PC and
the PC can temporarily suspend the round-robin route collection
(with its multiple tiers of collection) process and stream the
required amount of data for a point of its choosing. Embodiments
may include various advanced processing techniques such as envelope
processing, wavelet analysis, as well as many other signal
processing techniques. In embodiments, after acquisition of this
data, the DAQ card set will continue with its route at the point it
was interrupted. In embodiments, various PC scheduled data
acquisitions will follow their own schedules which will be less
frequency than the DAQ card route. They may be set up hourly,
daily, by number of route cycles (for example, once every 10
cycles) and also increased scheduling-wise based on their alarm
severity priority or type of measurement (e.g., motors may be
monitored differently than fans).
[0270] Embodiments of the methods and systems disclosed herein may
include data acquisition parking features. In embodiments, a data
acquisition box used for route collection, real time analysis and
in general as an acquisition instrument can be detached from its PC
(tablet or otherwise) and powered by an external power supply or
suitable battery. In embodiments, the data collector still retains
continuous monitoring capability and its on-board firmware can
implement dedicated monitoring functions for an extended period of
time or can be controlled remotely for further analysis.
Embodiments of the methods and systems disclosed herein may include
extended statistical capabilities for continuous monitoring.
[0271] Embodiments of the methods and systems disclosed herein may
include ambient sensing plus local sensing plus vibration for
analysis. In embodiments, ambient environmental temperature and
pressure, sensed temperature and pressure may be combined with
long/medium term vibration analysis for prediction of any of a
range of conditions or characteristics. Variants may add infrared
sensing, infrared thermography, ultrasound, and many other types of
sensors and input types in combination with vibration or with each
other. Embodiments of the methods and systems disclosed herein may
include a smart route. In embodiments, the continuous monitoring
system's software will adapt/adjust the data collection sequence
based on statistics, analytics, data alarms and dynamic analysis.
Typically, the route is set based on the channels the sensors are
attached to. In embodiments, with the crosspoint switch, the Mux
can combine any input Mux channels to the (e.g., eight) output
channels. In embodiments, as channels go into alarm or the system
identifies key deviations, it will pause the normal route set in
the software to gather specific simultaneous data, from the
channels sharing key statistical changes, for more advanced
analysis. Embodiments include conducting a smart OD S or smart
transfer function.
[0272] Embodiments of the methods and systems disclosed herein may
include smart ODS and one or more transfer functions. In
embodiments, due to a system's multiplexer and crosspoint switch,
an ODS, a transfer function, or other special tests on all the
vibration sensors attached to a machine/structure can be performed
and show exactly how the machine's points are moving in
relationship to each other. In embodiments, 40-50 kHz and longer
data lengths (e.g., at least one minute) may be streamed, which may
reveal different information than what a normal ODS or transfer
function will show. In embodiments, the system will be able to
determine, based on the data/statistics/analytics to use, the smart
route feature that breaks from the standard route and conducts an
ODS across a machine, structure or multiple machines and structures
that might show a correlation because the conditions/data directs
it. In embodiments, for the transfer functions there may be an
impact hammer used on one channel and then compared against other
vibration sensors on the machine. In embodiments, the system may
use the condition changes such as load, speed, temperature or other
changes in the machine or system to conduct the transfer function.
In embodiments, different transfer functions may be compared to
each other over time. In embodiments, difference transfer functions
may be strung together like a movie that may show how the machinery
fault changes, such as a bearing that could show how it moves
through the four stages of bearing failure and so on. Embodiments
of the methods and systems disclosed herein may include a
hierarchical Mux.
[0273] With reference to FIG. 8, the present disclosure generally
includes digitally collecting or streaming waveform data 2010 from
a machine 2020 whose operational speed can vary from relatively
slow rotational or oscillational speeds to much higher speeds in
different situations. The waveform data 2010, at least on one
machine, may include data from a single axis sensor 2030 mounted at
an unchanging reference location 2040 and from a three-axis sensor
2050 mounted at changing locations (or located at multiple
locations), including location 2052. In embodiments, the waveform
data 2010 can be vibration data obtained simultaneously from each
sensor 2030, 2050 in a gap-free format for a duration of multiple
minutes with maximum resolvable frequencies sufficiently large to
capture periodic and transient impact events. By way of this
example, the waveform data 2010 can include vibration data that can
be used to create an operational deflecting shape. It can also be
used, as needed, to diagnose vibrations from which a machine repair
solution can be prescribed.
[0274] In embodiments, the machine 2020 can further include a
housing 2100 that can contain a drive motor 2110 that can drive a
shaft 2120. The shaft 2120 can be supported for rotation or
oscillation by a set of bearings 2130, such as including a first
bearing 2140 and a second bearing 2150. A data collection module
2160 can connect to (or be resident on) the machine 2020. In one
example, the data collection module 2160 can be located and
accessible through a cloud network facility 2170, can collect the
waveform data 2010 from the machine 2020, and deliver the waveform
data 2010 to a remote location. A working end 2180 of the drive
shaft 2120 of the machine 2020 can drive a windmill, a fan, a pump,
a drill, a gear system, a drive system, or other working element,
as the techniques described herein can apply to a wide range of
machines, equipment, tools, or the like that include rotating or
oscillating elements. In other instances, a generator can be
substituted for the motor 2110, and the working end of the drive
shaft 2120 can direct rotational energy to the generator to
generate power, rather than consume it.
[0275] In embodiments, the waveform data 2010 can be obtained using
a predetermined route format based on the layout of the machine
2020. The waveform data 2010 may include data from the single axis
sensor 2030 and the three-axis sensor 2050. The single-axis sensor
2030 can serve as a reference probe with its one channel of data
and can be fixed at the unchanging location 2040 on the machine
under survey. The three-axis sensor 2050 can serve as a tri-axial
probe (e.g., three orthogonal axes) with its three channels of data
and can be moved along a predetermined diagnostic route format from
one test point to the next test point. In one example, both sensors
2030, 2050 can be mounted manually to the machine 2020 and can
connect to a separate portable computer in certain service
examples. The reference probe can remain at one location while the
user can move the tri-axial vibration probe along the predetermined
route, such as from bearing-to-bearing on a machine. In this
example, the user is instructed to locate the sensors at the
predetermined locations to complete the survey (or portion thereof)
of the machine.
[0276] With reference to FIG. 9, a portion of an exemplary machine
2200 is shown having a tri-axial sensor 2210 mounted to a location
2220 associated with a motor bearing of the machine 2200 with an
output shaft 2230 and output member 2240 in accordance with the
present disclosure. With reference to FIG. 10, an exemplary machine
2300 is shown having a tri-axial sensor 2310 and a single-axis
vibration sensor 2320 serving as the reference sensor that is
attached on the machine 2300 at an unchanging location for the
duration of the vibration survey in accordance with the present
disclosure. The tri-axial sensor 2310 and the single-axis vibration
sensor 2320 can be connected to a data collection system 2330.
[0277] In further examples, the sensors and data acquisition
modules and equipment can be integral to, or resident on, the
rotating machine. By way of these examples, the machine can contain
many single axis sensors and many tri-axial sensors at
predetermined locations. The sensors can be originally installed
equipment and provided by the original equipment manufacturer or
installed at a different time in a retrofit application. The data
collection module 2160, or the like, can select and use one single
axis sensor and obtain data from it exclusively during the
collection of waveform data 2010 while moving to each of the
tri-axial sensors. The data collection module 2160 can be resident
on the machine 2020 and/or connect via the cloud network facility
2170.
[0278] With reference to FIG. 8, the various embodiments include
collecting the waveform data 2010 by digitally recording locally,
or streaming over, the cloud network facility 2170. The waveform
data 2010 can be collected so as to be gap-free with no
interruptions and, in some respects, can be similar to an analog
recording of waveform data. The waveform data 2010 from all of the
channels can be collected for one to two minutes depending on the
rotating or oscillating speed of the machine being monitored. In
embodiments, the data sampling rate can be at a relatively
high-sampling rate relative to the operating frequency of the
machine 2020.
[0279] In embodiments, a second reference sensor can be used, and a
fifth channel of data can be collected. As such, the single-axis
sensor can be the first channel and tri-axial vibration can occupy
the second, the third, and the fourth data channels. This second
reference sensor, like the first, can be a single axis sensor, such
as an accelerometer. In embodiments, the second reference sensor,
like the first reference sensor, can remain in the same location on
the machine for the entire vibration survey on that machine. The
location of the first reference sensor (i.e., the single axis
sensor) may be different than the location of the second reference
sensors (i.e., another single axis sensor). In certain examples,
the second reference sensor can be used when the machine has two
shafts with different operating speeds, with the two reference
sensors being located on the two different shafts. In accordance
with this example, further single-axis reference sensors can be
employed at additional but different unchanging locations
associated with the rotating machine.
[0280] In embodiments, the waveform data can be transmitted
electronically in a gap-free free format at a significantly high
rate of sampling for a relatively longer period of time. In one
example, the period of time is 60 seconds to 120 seconds. In
another example, the rate of sampling is 100 kHz with a maximum
resolvable frequency (Fmax) of 40 kHz. It will be appreciated in
light of this disclosure that the waveform data can be shown to
approximate more closely some of the wealth of data available from
previous instances of analog recording of waveform data.
[0281] In embodiments, sampling, band selection, and filtering
techniques can permit one or more portions of a long stream of data
(i.e., one to two minutes in duration) to be under sampled or over
sampled to realize varying effective sampling rates. To this end,
interpolation and decimation can be used to further realize varying
effective sampling rates. For example, oversampling may be applied
to frequency bands that are proximal to rotational or oscillational
operating speeds of the sampled machine, or to harmonics thereof,
as vibration effects may tend to be more pronounced at those
frequencies across the operating range of the machine. In
embodiments, the digitally-sampled data set can be decimated to
produce a lower sampling rate. It will be appreciated in light of
the disclosure that decimate in this context can be the opposite of
interpolate. In embodiments, decimating the data set can include
first applying a low-pass filter to the digitally-sampled data set
and then undersampling the data set.
[0282] In one example, a sample waveform at 100 Hz can be
undersampled at every tenth point of the digital waveform to
produce an effective sampling rate of 10 Hz, but the remaining nine
points of that portion of the waveform are effectively discarded
and not included in the modeling of the sample waveform. Moreover,
this type of bare undersampling can create ghost frequencies due to
the undersampling rate (i.e., 10 Hz) relative to the 100 Hz sample
waveform.
[0283] Most hardware for analog-to-digital conversions uses a
sample-and-hold circuit that can charge up a capacitor for a given
amount of time such that an average value of the waveform is
determined over a specific change in time. It will be appreciated
in light of the disclosure that the value of the waveform over the
specific change in time is not linear but more similar to a
cardinal sinusoidal ("sinc") function; therefore, it can be shown
that more emphasis can be placed on the waveform data at the center
of the sampling interval with exponential decay of the cardinal
sinusoidal signal occurring from its center.
[0284] By way of the above example, the sample waveform at 100 Hz
can be hardware-sampled at 10 Hz and therefore each sampling point
is averaged over 100 milliseconds (e.g., a signal sampled at 100 Hz
can have each point averaged over 10 milliseconds). In contrast to
the effective discarding of nine out of the ten data points of the
sampled waveform as discussed above, the present disclosure can
include weighing adjacent data. The adjacent data can refer to the
sample points that were previously discarded and the one remaining
point that was retained. In one example, a low pass filter can
average the adjacent sample data linearly, i.e., determining the
sum of every ten points and then dividing that sum by ten. In a
further example, the adjacent data can be weighted with a sinc
function. The process of weighting the original waveform with the
sinc function can be referred to as an impulse function, or can be
referred to in the time domain as a convolution.
[0285] The present disclosure can be applicable to not only
digitizing a waveform signal based on a detected voltage, but can
also be applicable to digitizing waveform signals based on current
waveforms, vibration waveforms, and image processing signals
including video signal rasterization. In one example, the resizing
of a window on a computer screen can be decimated, albeit in at
least two directions. In these further examples, it will be
appreciated that undersampling by itself can be shown to be
insufficient. To that end, oversampling or upsampling by itself can
similarly be shown to be insufficient, such that interpolation can
be used like decimation but in lieu of only undersampling by
itself.
[0286] It will be appreciated in light of the disclosure that
interpolation in this context can refer to first applying a low
pass filter to the digitally-sampled waveform data and then
upsampling the waveform data. It will be appreciated in light of
the disclosure that real-world examples can often require the use
of use non-integer factors for decimation or interpolation, or
both. To that end, the present disclosure includes interpolating
and decimating sequentially in order to realize a non-integer
factor rate for interpolating and decimating. In one example,
interpolating and decimating sequentially can define applying a
low-pass filter to the sample waveform, then interpolating the
waveform after the low-pass filter, and then decimating the
waveform after the interpolation. In embodiments, the vibration
data can be looped to purposely emulate conventional tape recorder
loops, with digital filtering techniques used with the effective
splice to facilitate longer analyses. It will be appreciated in
light of the disclosure that the above techniques do not preclude
waveform, spectrum, and other types of analyses to be processed and
displayed with a GUI of the user at the time of collection. It will
be appreciated in light of the disclosure that newer systems can
permit this functionality to be performed in parallel to the
high-performance collection of the raw waveform data.
[0287] With respect to time of collection issues, it will be
appreciated that older systems using the compromised approach of
improving data resolution, by collecting at different sampling
rates and data lengths, do not in fact save as much time as
expected. To that end, every time the data acquisition hardware is
stopped and started, latency issues can be created, especially when
there is hardware auto-scaling performed. The same can be true with
respect to data retrieval of the route information (i.e., test
locations) that is often in a database format and can be
exceedingly slow. The storage of the raw data in bursts to disk
(whether solid state or otherwise) can also be undesirably
slow.
[0288] In contrast, the many embodiments include digitally
streaming the waveform data 2010, as disclosed herein, and also
enjoying the benefit of needing to load the route parameter
information while setting the data acquisition hardware only once.
Because the waveform data 2010 is streamed to only one file, there
is no need to open and close files, or switch between loading and
writing operations with the storage medium. It can be shown that
the collection and storage of the waveform data 2010, as described
herein, can be shown to produce relatively more meaningful data in
significantly less time than the traditional batch data acquisition
approach. An example of this includes an electric motor about which
waveform data can be collected with a data length of 4K points
(i.e., 4,096) for sufficiently high resolution in order to, among
other things, distinguish electrical sideband frequencies. For fans
or blowers, a reduced resolution of 1K (i.e., 1,024) can be used.
In certain instances, 1K can be the minimum waveform data length
requirement. The sampling rate can be 1,280 Hz and that equates to
an Fmax of 500 Hz. It will be appreciated in light of the
disclosure that oversampling by an industry standard factor of 2.56
can satisfy the necessary two-times (2.times.) oversampling for the
Nyquist Criterion with some additional leeway that can accommodate
anti-aliasing filter-rolloff. The time to acquire this waveform
data would be 1,024 points at 1,280 hertz, which are 800
milliseconds.
[0289] To improve accuracy, the waveform data can be averaged.
Eight averages can be used with, for example, fifty percent
overlap. This would extend the time from 800 milliseconds to 3.6
seconds, which is equal to 800 msec.times.8 averages.times.0.5
(overlap ratio)+0.5.times.800 msec (non-overlapped head and tail
ends). After collection at Fmax=500 Hz waveform data, a higher
sampling rate can be used. In one example, ten times (10.times.)
the previous sampling rate can be used and Fmax=10 kHz. By way of
this example, eight averages can be used with fifty percent (50%)
overlap to collect waveform data at this higher rate that can
amount to a collection time of 360 msec or 0.36 seconds. It will be
appreciated in light of the disclosure that it can be necessary to
read the hardware collection parameters for the higher sampling
rate from the route list, as well as permit hardware auto-scaling,
or the resetting of other necessary hardware collection parameters,
or both. To that end, a few seconds of latency can be added to
accommodate the changes in sampling rate. In other instances,
introducing latency can accommodate hardware autoscaling and
changes to hardware collection parameters that can be required when
using the lower sampling rate disclosed herein. In addition to
accommodating the change in sampling rate, additional time is
needed for reading the route point information from the database
(i.e., where to monitor and where to monitor next), displaying the
route information, and processing the waveform data. Moreover,
display of the waveform data and/or associated spectra can also
consume significant time. In light of the above, 15 seconds to 20
seconds can elapse while obtaining waveform data at each
measurement point.
[0290] In further examples, additional sampling rates can be added
but this can make the total amount time for the vibration survey
even longer because time adds up from changeover time from one
sampling rate to another and from the time to obtain additional
data at different sampling rate. In one example, a lower sampling
rate is used, such as a sampling rate of 128 Hz where Fmax=50 Hz.
By way of this example, the vibration survey would, therefore,
require an additional 36 seconds for the first set of averaged data
at this sampling rate, in addition to others mentioned above, and
consequently the total time spent at each measurement point
increases even more dramatically. Further embodiments include using
similar digital streaming of gap free waveform data as disclosed
herein for use with wind turbines and other machines that can have
relatively slow speed rotating or oscillating systems. In many
examples, the waveform data collected can include long samples of
data at a relatively high-sampling rate. In one example, the
sampling rate can be 100 kHz and the sampling duration can be for
two minutes on all of the channels being recorded. In many
examples, one channel can be for the single axis reference sensor
and three more data channels can be for the tri-axial three channel
sensor. It will be appreciated in light of the disclosure that the
long data length can be shown to facilitate detection of extremely
low frequency phenomena. The long data length can also be shown to
accommodate the inherent speed variability in wind turbine
operations. Additionally, the long data length can further be shown
to provide the opportunity for using numerous averages such as
those discussed herein, to achieve very high spectral resolution,
and to make feasible tape loops for certain spectral analyses. Many
multiple advanced analytical techniques can now become available
because such techniques can use the available long uninterrupted
length of waveform data in accordance with the present
disclosure.
[0291] It will also be appreciated in light of the disclosure that
the simultaneous collection of waveform data from multiple channels
can facilitate performing transfer functions between multiple
channels. Moreover, the simultaneous collection of waveform data
from multiple channels facilitates establishing phase relationships
across the machine so that more sophisticated correlations can be
utilized by relying on the fact that the waveforms from each of the
channels are collected simultaneously. In other examples, more
channels in the data collection can be used to reduce the time it
takes to complete the overall vibration survey by allowing for
simultaneous acquisition of waveform data from multiple sensors
that otherwise would have to be acquired, in a subsequent fashion,
moving sensor to sensor in the vibration survey.
[0292] The present disclosure includes the use of at least one of
the single-axis reference probe on one of the channels to allow for
acquisition of relative phase comparisons between channels. The
reference probe can be an accelerometer or other type of transducer
that is not moved and, therefore, fixed at an unchanging location
during the vibration survey of one machine. Multiple reference
probes can each be deployed as at suitable locations fixed in place
(i.e., at unchanging locations) throughout the acquisition of
vibration data during the vibration survey. In certain examples, up
to seven reference probes can be deployed depending on the capacity
of the data collection module 2160 or the like. Using transfer
functions or similar techniques, the relative phases of all
channels may be compared with one another at all selected
frequencies. By keeping the one or more reference probes fixed at
their unchanging locations while moving or monitoring the other
tri-axial vibration sensors, it can be shown that the entire
machine can be mapped with regard to amplitude and relative phase.
This can be shown to be true even when there are more measurement
points than channels of data collection. With this information, an
operating deflection shape can be created that can show dynamic
movements of the machine in 3D, which can provide an invaluable
diagnostic tool. In embodiments, the one or more reference probes
can provide relative phase, rather than absolute phase. It will be
appreciated in light of the disclosure that relative phase may not
be as valuable absolute phase for some purposes, but the relative
phase the information can still be shown to be very useful.
[0293] In embodiments, the sampling rates used during the vibration
survey can be digitally synchronized to predetermined operational
frequencies that can relate to pertinent parameters of the machine
such as rotating or oscillating speed. Doing this, permits
extracting even more information using synchronized averaging
techniques. It will be appreciated in light of the disclosure that
this can be done without the use of a key phasor or a reference
pulse from a rotating shaft, which is usually not available for
route collected data. As such, non-synchronous signals can be
removed from a complex signal without the need to deploy
synchronous averaging using the key phasor. This can be shown to be
very powerful when analyzing a particular pinion in a gearbox or
generally applied to any component within a complicated mechanical
mechanism. In many instances, the key phasor or the reference pulse
is rarely available with route collected data, but the techniques
disclosed herein can overcome this absence. In embodiments, there
can be multiple shafts running at different speeds within the
machine being analyzed. In certain instances, there can be a
single-axis reference probe for each shaft. In other instances, it
is possible to relate the phase of one shaft to another shaft using
only one single axis reference probe on one shaft at its unchanging
location. In embodiments, variable speed equipment can be more
readily analyzed with relatively longer duration of data relative
to single speed equipment. The vibration survey can be conducted at
several machine speeds within the same contiguous set of vibration
data using the same techniques disclosed herein. These techniques
can also permit the study of the change of the relationship between
vibration and the change of the rate of speed that was not
available before.
[0294] In embodiments, there are numerous analytical techniques
that can emerge from because raw waveform data can be captured in a
gap-free digital format as disclosed herein. The gap-free digital
format can facilitate many paths to analyze the waveform data in
many ways after the fact to identify specific problems. The
vibration data collected in accordance with the techniques
disclosed herein can provide the analysis of transient,
semi-periodic and very low frequency phenomena. The waveform data
acquired in accordance with the present disclosure can contain
relatively longer streams of raw gap-free waveform data that can be
conveniently played back as needed, and on which many and varied
sophisticated analytical techniques can be performed. A large
number of such techniques can provide for various forms of
filtering to extract low amplitude modulations from transient
impact data that can be included in the relatively longer stream of
raw gap-free waveform data. It will be appreciated in light of the
disclosure that in past data collection practices, these types of
phenomena were typically lost by the averaging process of the
spectral processing algorithms because the goal of the previous
data acquisition module was purely periodic signals; or these
phenomena were lost to file size reduction methodologies due to the
fact that much of the content from an original raw signal was
typically discarded knowing it would not be used.
[0295] In embodiments, there is a method of monitoring vibration of
a machine having at least one shaft supported by a set of bearings.
The method includes monitoring a first data channel assigned to a
single-axis sensor at an unchanging location associated with the
machine. The method also includes monitoring a second, third, and
fourth data channel assigned to a three-axis sensor. The method
further includes recording gap-free digital waveform data
simultaneously from all of the data channels while the machine is
in operation; and determining a change in relative phase based on
the digital waveform data. The method also includes the tri-axial
sensor being located at a plurality of positions associated with
the machine while obtaining the digital waveform. In embodiments,
the second, third, and fourth channels are assigned together to a
sequence of tri-axial sensors each located at different positions
associated with the machine. In embodiments, the data is received
from all of the sensors on all of their channels
simultaneously.
[0296] The method also includes determining an operating deflection
shape based on the change in relative phase information and the
waveform data. In embodiments, the unchanging location of the
reference sensor is a position associated with a shaft of the
machine. In embodiments, the tri-axial sensors in the sequence of
the tri-axial sensors are each located at different positions and
are each associated with different bearings in the machine. In
embodiments, the unchanging location is a position associated with
a shaft of the machine and, wherein, the tri-axial sensors in the
sequence of the tri-axial sensors are each located at different
positions and are each associated with different bearings that
support the shaft in the machine. The various embodiments include
methods of sequentially monitoring vibration or similar process
parameters and signals of a rotating or oscillating machine or
analogous process machinery from a number of channels
simultaneously, which can be known as an ensemble. In various
examples, the ensemble can include one to eight channels. In
further examples, an ensemble can represent a logical measurement
grouping on the equipment being monitored whether those measurement
locations are temporary for measurement, supplied by the original
equipment manufacturer, retrofit at a later date, or one or more
combinations thereof.
[0297] In one example, an ensemble can monitor bearing vibration in
a single direction. In a further example, an ensemble can monitor
three different directions (e.g., orthogonal directions) using a
tri-axial sensor. In yet further examples, an ensemble can monitor
four or more channels where the first channel can monitor a single
axis vibration sensor, and the second, the third, and the fourth
channels can monitor each of the three directions of the tri-axial
sensor. In other examples, the ensemble can be fixed to a group of
adjacent bearings on the same piece of equipment or an associated
shaft. The various embodiments provide methods that include
strategies for collecting waveform data from various ensembles
deployed in vibration studies or the like in a relatively more
efficient manner. The methods also include simultaneously
monitoring of a reference channel assigned to an unchanging
reference location associated with the ensemble monitoring the
machine. The cooperation with the reference channel can be shown to
support a more complete correlation of the collected waveforms from
the ensembles. The reference sensor on the reference channel can be
a single axis vibration sensor, or a phase reference sensor that
can be triggered by a reference location on a rotating shaft or the
like. As disclosed herein, the methods can further include
recording gap-free digital waveform data simultaneously from all of
the channels of each ensemble at a relatively high rate of sampling
so as to include all frequencies deemed necessary for the proper
analysis of the machinery being monitored while it is in operation.
The data from the ensembles can be streamed gap-free to a storage
medium for subsequent processing that can be connected to a cloud
network facility, a local data link, Bluetooth.TM. connectivity,
cellular data connectivity, or the like.
[0298] In embodiments, the methods disclosed herein include
strategies for collecting data from the various ensembles including
digital signal processing techniques that can be subsequently
applied to data from the ensembles to emphasize or better isolate
specific frequencies or waveform phenomena. This can be in contrast
with current methods that collect multiple sets of data at
different sampling rates, or with different hardware filtering
configurations including integration, that provide relatively less
post-processing flexibility because of the commitment to these same
(known as a priori hardware configurations). These same hardware
configurations can also be shown to increase time of the vibration
survey due to the latency delays associated with configuring the
hardware for each independent test. In embodiments, the methods for
collecting data from various ensembles include data marker
technology that can be used for classifying sections of streamed
data as homogenous and belonging to a specific ensemble. In one
example, a classification can be defined as operating speed. In
doing so, a multitude of ensembles can be created from what
conventional systems would collect as only one. The many
embodiments include post-processing analytic techniques for
comparing the relative phases of all the frequencies of interest
not only between each channel of the collected ensemble but also
between all of the channels of all of the ensembles being
monitored, when applicable.
[0299] With reference to FIG. 12, the many embodiments include a
first machine 2400 having rotating or oscillating components 2410,
or both, each supported by a set of bearings 2420 including a
bearing pack 2422, a bearing pack 2424, a bearing pack 2426, and
more as needed. The first machine 2400 can be monitored by a first
sensor ensemble 2450. The first ensemble 2450 can be configured to
receive signals from sensors originally installed (or added later)
on the first machine 2400. The sensors on the machine 2400 can
include single-axis sensors 2460, such as a single-axis sensor
2462, a single-axis sensor 2464, and more as needed. In many
examples, the single axis-sensors 2460 can be positioned in the
machine 2400 at locations that allow for the sensing of one of the
rotating or oscillating components 2410 of the machine 2400.
[0300] The machine 2400 can also have tri-axial (e.g., orthogonal
axes) sensors 2480, such as a tri-axial sensor 2482, a tri-axial
sensor 2484, and more as needed. In many examples, the tri-axial
sensors 2480 can be positioned in the machine 2400 at locations
that allow for the sensing of one of each of the bearing packs in
the sets of bearings 2420 that is associated with the rotating or
oscillating components of the machine 2400. The machine 2400 can
also have temperature sensors 2500, such as a temperature sensor
2502, a temperature sensor 2504, and more as needed. The machine
2400 can also have a tachometer sensor 2510 or more as needed that
each detail the RPMs of one of its rotating components. By way of
the above example, the first sensor ensemble 2450 can survey the
above sensors associated with the first machine 2400. To that end,
the first ensemble 2450 can be configured to receive eight
channels. In other examples, the first sensor ensemble 2450 can be
configured to have more than eight channels, or less than eight
channels as needed. In this example, the eight channels include two
channels that can each monitor a single-axis reference sensor
signal and three channels that can monitor a tri-axial sensor
signal. The remaining three channels can monitor two temperature
signals and a signal from a tachometer. In one example, the first
ensemble 2450 can monitor the single-axis sensor 2462, the
single-axis sensor 2464, the tri-axial sensor 2482, the temperature
sensor 2502, the temperature sensor 2504, and the tachometer sensor
2510 in accordance with the present disclosure. During a vibration
survey on the machine 2400, the first ensemble 2450 can first
monitor the tri-axial sensor 2482 and then move next to the
tri-axial sensor 2484.
[0301] After monitoring the tri-axial sensor 2484, the first
ensemble 2450 can monitor additional tri-axial sensors on the
machine 2400 as needed and that are part of the predetermined route
list associated with the vibration survey of the machine 2400, in
accordance with the present disclosure. During this vibration
survey, the first ensemble 2450 can continually monitor the
single-axis sensor 2462, the single-axis sensor 2464, the two
temperature sensors 2502, 2504, and the tachometer sensor 2510
while the first ensemble 2450 can serially monitor the multiple
tri-axial sensors 2480 in the pre-determined route plan for this
vibration survey.
[0302] With reference to FIG. 12, the many embodiments include a
second machine 2600 having rotating or oscillating components 2610,
or both, each supported by a set of bearings 2620 including a
bearing pack 2622, a bearing pack 2624, a bearing pack 2626, and
more as needed. The second machine 2600 can be monitored by a
second sensor ensemble 2650. The second ensemble 2650 can be
configured to receive signals from sensors originally installed (or
added later) on the second machine 2600. The sensors on the machine
2600 can include single-axis sensors 2660, such as a single-axis
sensor 2662, a single-axis sensor 2664, and more as needed. In many
examples, the single axis-sensors 2660 can be positioned in the
machine 2600 at locations that allow for the sensing of one of the
rotating or oscillating components 2610 of the machine 2600.
[0303] The machine 2600 can also have tri-axial (e.g., orthogonal
axes) sensors 2680, such as a tri-axial sensor 2682, a tri-axial
sensor 2684, a tri-axial sensor 2686, a tri-axial sensor 2688, and
more as needed. In many examples, the tri-axial sensors 2680 can be
positioned in the machine 2600 at locations that allow for the
sensing of one of each of the bearing packs in the sets of bearings
2620 that is associated with the rotating or oscillating components
of the machine 2600. The machine 2600 can also have temperature
sensors 2700, such as a temperature sensor 2702, a temperature
sensor 2704, and more as needed. The machine 2600 can also have a
tachometer sensor 2710 or more as needed that each detail the RPMs
of one of its rotating components.
[0304] By way of the above example, the second sensor ensemble 2650
can survey the above sensors associated with the second machine
2600. To that end, the second ensemble 2650 can be configured to
receive eight channels. In other examples, the second sensor
ensemble 2650 can be configured to have more than eight channels or
less than eight channels as needed. In this example, the eight
channels include one channel that can monitor a single-axis
reference sensor signal and six channels that can monitor two
tri-axial sensor signals. The remaining channel can monitor a
temperature signal. In one example, the second ensemble 2650 can
monitor the single axis sensor 2662, the tri-axial sensor 2682, the
tri-axial sensor 2684, and the temperature sensor 2702. During a
vibration survey on the machine 2600 in accordance with the present
disclosure, the second ensemble 2650 can first monitor the
tri-axial sensor 2682 simultaneously with the tri-axial sensor 2684
and then move onto the tri-axial sensor 2686 simultaneously with
the tri-axial sensor 2688.
[0305] After monitoring the tri-axial sensors 2680, the second
ensemble 2650 can monitor additional tri-axial sensors (in
simultaneous pairs) on the machine 2600 as needed and that are part
of the predetermined route list associated with the vibration
survey of the machine 2600 in accordance with the present
disclosure. During this vibration survey, the second ensemble 2650
can continually monitor the single-axis sensor 2662 at its
unchanging location and the temperature sensor 2702 while the
second ensemble 2650 can serially monitor the multiple tri-axial
sensors in the pre-determined route plan for this vibration
survey.
[0306] With continuing reference to FIG. 12, the many embodiments
include a third machine 2800 having rotating or oscillating
components 2810, or both, each supported by a set of bearings 2820
including a bearing pack 2822, a bearing pack 2824, a bearing pack
2826, and more as needed. The third machine 2800 can be monitored
by a third sensor ensemble 2850. The third ensemble 2850 can be
configured with a single-axis sensor 2860, and two tri-axial (e.g.,
orthogonal axes) sensors 2880, 2882. In many examples, the single
axis-sensor 2860 can be secured by the user on the machine 2800 at
a location that allows for the sensing of one of the rotating or
oscillating components of the machine 2800. The tri-axial sensors
2880, 2882 can be also be located on the machine 2800 by the user
at locations that allow for the sensing of one of each of the
bearings in the sets of bearings that each associated with the
rotating or oscillating components of the machine 2800. The third
ensemble 2850 can also include a temperature sensor 2900. The third
ensemble 2850 and its sensors can be moved to other machines unlike
the first and second ensembles 2450, 2650.
[0307] The many embodiments also include a fourth machine 2950
having rotating or oscillating components 2960, or both, each
supported by a set of bearings 2970 including a bearing pack 2972,
a bearing pack 2974, a bearing pack 2976, and more as needed. The
fourth machine 2950 can be also monitored by the third sensor
ensemble 2850 when the user moves it to the fourth machine 2950.
The many embodiments also include a fifth machine 3000 having
rotating or oscillating components 3010, or both. The fifth machine
3000 may not be explicitly monitored by any sensor or any sensor
ensembles in operation but it can create vibrations or other
impulse energy of sufficient magnitude to be recorded in the data
associated with any one of the machines 2400, 2600, 2800, 2950
under a vibration survey.
[0308] The many embodiments include monitoring the first sensor
ensemble 2450 on the first machine 2400 through the predetermined
route as disclosed herein. The many embodiments also include
monitoring the second sensor ensemble 2650 on the second machine
2600 through the predetermined route. The locations of machine 2400
being close to machine 2600 can be included in the contextual
metadata of both vibration surveys. The third ensemble 2850 can be
moved between machine 2800, machine 2950, and other suitable
machines. The machine 3000 has no sensors onboard as configured,
but could be monitored as needed by the third sensor ensemble 2850.
The machine 3000 and its operational characteristics can be
recorded in the metadata in relation to the vibration surveys on
the other machines to note its contribution due to its
proximity.
[0309] The many embodiments include hybrid database adaptation for
harmonizing relational metadata and streaming raw data formats.
Unlike older systems that utilized traditional database structure
for associating nameplate and operational parameters (sometimes
deemed metadata) with individual data measurements that are
discrete and relatively simple, it will be appreciated in light of
the disclosure that more modern systems can collect relatively
larger quantities of raw streaming data with higher sampling rates
and greater resolutions. At the same time, it will also be
appreciated in light of the disclosure that the network of metadata
with which to link and obtain this raw data or correlate with this
raw data, or both, is expanding at ever-increasing rates.
[0310] In one example, a single overall vibration level can be
collected as part of a route or prescribed list of measurement
points. This data collected can then be associated with database
measurement location information for a point located on a surface
of a bearing housing on a specific piece of the machine adjacent to
a coupling in a vertical direction. Machinery analysis parameters
relevant to the proper analysis can be associated with the point
located on the surface. Examples of machinery analysis parameters
relevant to the proper analysis can include a running speed of a
shaft passing through the measurement point on the surface. Further
examples of machinery analysis parameters relevant to the proper
analysis can include one of, or a combination of: running speeds of
all component shafts for that piece of equipment and/or machine,
bearing types being analyzed such as sleeve or rolling element
bearings, the number of gear teeth on gears should there be a
gearbox, the number of poles in a motor, slip and line frequency of
a motor, roller bearing element dimensions, number of fan blades,
or the like. Examples of machinery analysis parameters relevant to
the proper analysis can further include machine operating
conditions such as the load on the machines and whether load is
expressed in percentage, wattage, air flow, head pressure,
horsepower, and the like. Further examples of machinery analysis
parameters include information relevant to adjacent machines that
might influence the data obtained during the vibration study.
[0311] It will be appreciated in light of the disclosure that the
vast array of equipment and machinery types can support many
different classifications, each of which can be analyzed in
distinctly different ways. For example, some machines, like screw
compressors and hammer mills, can be shown to run much noisier and
can be expected to vibrate significantly more than other machines.
Machines known to vibrate more significantly can be shown to
require a change in vibration levels that can be considered
acceptable relative to quieter machines.
[0312] The present disclosure further includes hierarchical
relationships found in the vibrational data collected that can be
used to support proper analysis of the data. One example of the
hierarchical data includes the interconnection of mechanical
componentry such as a bearing being measured in a vibration survey
and the relationship between that bearing, including how that
bearing connects to a particular shaft on which is mounted a
specific pinion within a particular gearbox, and the relationship
between the shaft, the pinion, and the gearbox. The hierarchical
data can further include in what particular spot within a machinery
gear train that the bearing being monitored is located relative to
other components in the machine. The hierarchical data can also
detail whether the bearing being measured in a machine is in close
proximity to another machine whose vibrations may affect what is
being measured in the machine that is the subject of the vibration
study.
[0313] The analysis of the vibration data from the bearing or other
components related to one another in the hierarchical data can use
table lookups, searches for correlations between frequency patterns
derived from the raw data, and specific frequencies from the
metadata of the machine. In some embodiments, the above can be
stored in and retrieved from a relational database. In embodiments,
National Instrument's Technical Data Management Solution (TDMS)
file format can be used. The TDMS file format can be optimized for
streaming various types of measurement data (i.e., binary digital
samples of waveforms), as well as also being able to handle
hierarchical metadata.
[0314] The many embodiments include a hybrid relational
metadata-binary storage approach (HRM-BSA). The HRM-BSA can include
a structured query language (SQL) based relational database engine.
The structured query language based relational database engine can
also include a raw data engine that can be optimized for throughput
and storage density for data that is flat and relatively
structureless. It will be appreciated in light of the disclosure
that benefits can be shown in the cooperation between the
hierarchical metadata and the SQL relational database engine. In
one example, marker technologies and pointer sign-posts can be used
to make correlations between the raw database engine and the SQL
relational database engine. Three examples of correlations between
the raw database engine and the SQL relational database engine
linkages include: (1) pointers from the SQL database to the raw
data; (2) pointers from the ancillary metadata tables or similar
grouping of the raw data to the SQL database; and (3) independent
storage tables outside the domain of either the SQL database or raw
data technologies.
[0315] With reference to FIG. 13, the present disclosure can
include pointers for Group 1 and Group 2 that can include
associated filenames, path information, table names, database key
fields as employed with existing SQL database technologies that can
be used to associate a specific database segments or locations,
asset properties to specific measurement raw data streams, records
with associated time/date stamps, or associated metadata such as
operating parameters, panel conditions, and the like. By way of
this example, a plant 3200 can include machine one 3202, machine
two 3204, and many others in the plant 3200. The machine one 3202
can include a gearbox 3210, a motor 3212, and other elements. The
machine two 3204 can include a motor 3220, and other elements. Many
waveforms 3230 including waveform 3240, waveform 3242, waveform
3244, and additional waveforms as needed can be acquired from the
machines 3202, 3204 in the plant 3200. The waveforms 3230 can be
associated with the local marker linking tables 3300 and the
linking raw data tables 3400. The machines 3202, 3204 and their
elements can be associated with linking tables having relational
databases 3500. The linking tables raw data tables 3400 and the
linking tables having relational databases 3500 can be associated
with the linking tables with optional independent storage tables
3600.
[0316] The present disclosure can include markers that can be
applied to a time mark or a sample length within the raw waveform
data. The markers generally fall into two categories: preset or
dynamic. The preset markers can correlate to preset or existing
operating conditions (e.g., load, head pressure, air flow cubic
feet per minute, ambient temperature, RPMs, and the like.). These
preset markers can be fed into the data acquisition system
directly. In certain instances, the preset markers can be collected
on data channels in parallel with the waveform data (e.g.,
waveforms for vibration, current, voltage, etc.). Alternatively,
the values for the preset markers can be entered manually.
[0317] For dynamic markers such as trending data, it can be
important to compare similar data like comparing vibration
amplitudes and patterns with a repeatable set of operating
parameters. One example of the present disclosure includes one of
the parallel channel inputs being a key phasor trigger pulse from
an operating shaft that can provide RPM information at the
instantaneous time of collection. In this example of dynamic
markers, sections of collected waveform data can be marked with
appropriate speeds or speed ranges.
[0318] The present disclosure can also include dynamic markers that
can correlate to data that can be derived from post processing and
analytics performed on the sample waveform. In further embodiments,
the dynamic markers can also correlate to post-collection derived
parameters including RPMs, as well as other operationally derived
metrics such as alarm conditions like a maximum RPM. In certain
examples, many modern pieces of equipment that are candidates for a
vibration survey with the portable data collection systems
described herein do not include tachometer information. This can be
true because it is not always practical or cost justifiable to add
a tachometer even though the measurement of RPM can be of primary
importance for the vibration survey and analysis. It will be
appreciated that for fixed speed machinery obtaining an accurate
RPM measurement can be less important especially when the
approximate speed of the machine can be ascertained before-hand;
however, variable-speed drives are becoming more and more
prevalent. It will also be appreciated in light of the disclosure
that various signal processing techniques can permit the derivation
of RPM from the raw data without the need for a dedicated
tachometer signal.
[0319] In many embodiments, the RPM information can be used to mark
segments of the raw waveform data over its collection history.
Further embodiments include techniques for collecting instrument
data following a prescribed route of a vibration study. The dynamic
markers can enable analysis and trending software to utilize
multiple segments of the collection interval indicated by the
markers (e.g., two minutes) as multiple historical collection
ensembles, rather than just one as done in previous systems where
route collection systems would historically store data for only one
RPM setting. This could, in turn, be extended to any other
operational parameter such as load setting, ambient temperature,
and the like, as previously described. The dynamic markers,
however, that can be placed in a type of index file pointing to the
raw data stream can classify portions of the stream in homogenous
entities that can be more readily compared to previously collected
portions of the raw data stream
[0320] The many embodiments include the hybrid relational
metadata-binary storage approach that can use the best of
pre-existing technologies for both relational and raw data streams.
In embodiments, the hybrid relational metadata-binary storage
approach can marry them together with a variety of marker linkages.
The marker linkages can permit rapid searches through the
relational metadata and can allow for more efficient analyses of
the raw data using conventional SQL techniques with pre-existing
technology. This can be shown to permit utilization of many of the
capabilities, linkages, compatibilities, and extensions that
conventional database technologies do not provide.
[0321] The marker linkages can also permit rapid and efficient
storage of the raw data using conventional binary storage and data
compression techniques. This can be shown to permit utilization of
many of the capabilities, linkages, compatibilities, and extensions
that conventional raw data technologies provide such as TMDS
(National Instruments), UFF (Universal File Format such as UFF58),
and the like. The marker linkages can further permit using the
marker technology links where a vastly richer set of data from the
ensembles can be amassed in the same collection time as more
conventional systems. The richer set of data from the ensembles can
store data snapshots associated with predetermined collection
criterion and the proposed system can derive multiple snapshots
from the collected data streams utilizing the marker technology. In
doing so, it can be shown that a relatively richer analysis of the
collected data can be achieved. One such benefit can include more
trending points of vibration at a specific frequency or order of
running speed versus RPM, load, operating temperature, flow rates,
and the like, which can be collected for a similar time relative to
what is spent collecting data with a conventional system.
[0322] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from machines, elements of the machines and the environment
of the machines including heavy duty machines deployed at a local
job site or at distributed job sites under common control. The
heavy-duty machines may include earthmoving equipment, heavy duty
on-road industrial vehicles, heavy duty off-road industrial
vehicles, industrial machines deployed in various settings such as
turbines, turbomachinery, generators, pumps, pulley systems,
manifold and valve systems, and the like. In embodiments, heavy
industrial machinery may also include earth-moving equipment,
earth-compacting equipment, hauling equipment, hoisting equipment,
conveying equipment, aggregate production equipment, equipment used
in concrete construction, and piledriving equipment. In examples,
earth moving equipment may include excavators, backhoes, loaders,
bulldozers, skid steer loaders, trenchers, motor graders, motor
scrapers, crawler loaders, and wheeled loading shovels. In
examples, construction vehicles may include dumpers, tankers,
tippers, and trailers. In examples, material handling equipment may
include cranes, conveyors, forklift, and hoists. In examples,
construction equipment may include tunnel and handling equipment,
road rollers, concrete mixers, hot mix plants, road making machines
(compactors), stone crashers, pavers, slurry seal machines,
spraying and plastering machines, and heavy-duty pumps. Further
examples of heavy industrial equipment may include different
systems such as implement traction, structure, power train,
control, and information. Heavy industrial equipment may include
many different powertrains and combinations thereof to provide
power for locomotion and to also provide power to accessories and
onboard functionality. In each of these examples, the platform 100
may deploy the local data collection system 102 into the
environment 104 in which these machines, motors, pumps, and the
like, operate and directly connected integrated into each of the
machines, motors, pumps, and the like.
[0323] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from machines in operation and machines in being
constructed such as turbine and generator sets like Siemens.TM.
SGT6-5000F.TM. gas turbine, an SST-900.TM. steam turbine, an
SGen6-1000A.TM. generator, and an SGen6-100A.TM. generator, and the
like. In embodiments, the local data collection system 102 may be
deployed to monitor steam turbines as they rotate in the currents
caused by hot water vapor that may be directed through the turbine
but otherwise generated from a different source such as from
gas-fired burners, nuclear cores, molten salt loops and the like.
In these systems, the local data collection system 102 may monitor
the turbines and the water or other fluids in a closed loop cycle
in which water condenses and is then heated until it evaporates
again. The local data collection system 102 may monitor the steam
turbines separately from the fuel source deployed to heat the water
to steam. In examples, working temperatures of steam turbines may
be between 500 and 650.degree. C. In many embodiments, an array of
steam turbines may be arranged and configured for high, medium, and
low pressure, so they may optimally convert the respective steam
pressure into rotational movement.
[0324] The local data collection system 102 may also be deployed in
a gas turbines arrangement and therefore not only monitor the
turbine in operation but also monitor the hot combustion gases feed
into the turbine that may be in excess of 1,500.degree. C. Because
these gases are much hotter than those in steam turbines, the
blades may be cooled with air that may flow out of small openings
to create a protective film or boundary layer between the exhaust
gases and the blades. This temperature profile may be monitored by
the local data collection system 102. Gas turbine engines, unlike
typical steam turbines, include a compressor, a combustion chamber,
and a turbine all of which are journaled for rotation with a
rotating shaft. The construction and operation of each of these
components may be monitored by the local data collection system
102.
[0325] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from water turbines serving as rotary engines that may
harvest energy from moving water and are used for electric power
generation. The type of water turbine or hydro-power selected for a
project may be based on the height of standing water, often
referred to as head, and the flow (or volume of water) at the site.
In this example, a generator may be placed at the top of a shaft
that connects to the water turbine. As the turbine catches the
naturally moving water in its blade and rotates, the turbine sends
rotational power to the generator to generate electrical energy. In
doing so, the platform 100 may monitor signals from the generators,
the turbines, the local water system, flow controls such as dam
windows and sluices. Moreover, the platform 100 may monitor local
conditions on the electric grid including load, predicted demand,
frequency response, and the like, and include such information in
the monitoring and control deployed by platform 100 in these
hydroelectric settings.
[0326] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from energy production environments, such as thermal,
nuclear, geothermal, chemical, biomass, carbon-based fuels,
hybrid-renewable energy plants, and the like. Many of these plants
may use multiple forms of energy harvesting equipment like wind
turbines, hydro turbines, and steam turbines powered by heat from
nuclear, gas-fired, solar, and molten salt heat sources. In
embodiments, elements in such systems may include transmission
lines, heat exchangers, desulphurization scrubbers, pumps, coolers,
recuperators, chillers, and the like. In embodiments, certain
implementations of turbomachinery, turbines, scroll compressors,
and the like may be configured in arrayed control so as to monitor
large facilities creating electricity for consumption, providing
refrigeration, creating steam for local manufacture and heating,
and the like, and that arrayed control platforms may be provided by
the provider of the industrial equipment such as Honeywell and
their Experion.TM. PKS platform. In embodiments, the platform 100
may specifically communicate with and integrate the local
manufacturer-specific controls and may allow equipment from one
manufacturer to communicate with other equipment. Moreover, the
platform 100 provides allows for the local data collection system
102 to collect information across systems from many different
manufacturers. In embodiments, the platform 100 may include the
local data collection system 102 deployed in the environment 104 to
monitor signals from marine industrial equipment, marine diesel
engines, shipbuilding, oil and gas plants, refineries,
petrochemical plant, ballast water treatment solutions, marine
pumps and turbines, and the like.
[0327] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from heavy industrial equipment and processes including
monitoring one or more sensors. By way of this example, sensors may
be devices that may be used to detect or respond to some type of
input from a physical environment, such as an electrical, heat, or
optical signal. In embodiments, the local data collection system
102 may include multiple sensors such as, without limitation, a
temperature sensor, a pressure sensor, a torque sensor, a flow
sensor, a heat sensor, a smoke sensor, an arc sensor, a radiation
sensor, a position sensor, an acceleration sensor, a strain sensor,
a pressure cycle sensor, a pressure sensor, an air temperature
sensor, and the like. The torque sensor may encompass a magnetic
twist angle sensor. In one example, the torque and speed sensors in
the local data collection system 102 may be similar to those
discussed in U.S. Pat. No. 8,352,149 to Meachem, issued 8 Jan. 2013
and hereby incorporated by reference as if fully set forth herein.
In embodiments, one or more sensors may be provided such as a
tactile sensor, a biosensor, a chemical sensor, an image sensor, a
humidity sensor, an inertial sensor, and the like.
[0328] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from sensors that may provide signals for fault detection
including excessive vibration, incorrect material, incorrect
material properties, trueness to the proper size, trueness to the
proper shape, proper weight, trueness to balance. Additional fault
sensors include those for inventory control and for inspections
such as to confirm that parts are packaged to plan, parts are to
tolerance in a plan, occurrence of packaging damage or stress, and
sensors that may indicate the occurrence of shock or damage in
transit. Additional fault sensors may include detection of the lack
of lubrication, over lubrication, the need for cleaning of the
sensor detection window, the need for maintenance due to low
lubrication, the need for maintenance due to blocking or reduced
flow in a lubrication region, and the like.
[0329] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 that includes
aircraft operations and manufacture including monitoring signals
from sensors for specialized applications such as sensors used in
an aircraft's Attitude and Heading Reference System (AHRS), such as
gyroscopes, accelerometers, and magnetometers. In embodiments, the
platform 100 may include the local data collection system 102
deployed in the environment 104 to monitor signals from image
sensors such as semiconductor charge coupled devices (CCDs), active
pixel sensors, in complementary metal-oxide-semiconductor (CMOS) or
N-type metal-oxide-semiconductor (NMOS, Live MOS) technologies. In
embodiments, the platform 100 may include the local data collection
system 102 deployed in the environment 104 to monitor signals from
sensors such as an infrared (IR) sensor, an ultraviolet (UV)
sensor, a touch sensor, a proximity sensor, and the like. In
embodiments, the platform 100 may include the local data collection
system 102 deployed in the environment 104 to monitor signals from
sensors configured for optical character recognition (OCR), reading
barcodes, detecting surface acoustic waves, detecting transponders,
communicating with home automation systems, medical diagnostics,
health monitoring, and the like.
[0330] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from sensors such as a Micro-Electro-Mechanical Systems
(MEMS) sensor, such as ST Microelectronic's.TM. LSM303AH smart MEMS
sensor, which may include an ultra-low-power high-performance
system-in-package featuring a 3D digital linear acceleration sensor
and a 3D digital magnetic sensor.
[0331] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from additional large machines such as turbines, windmills,
industrial vehicles, robots, and the like. These large mechanical
machines include multiple components and elements providing
multiple subsystems on each machine. To that end, the platform 100
may include the local data collection system 102 deployed in the
environment 104 to monitor signals from individual elements such as
axles, bearings, belts, buckets, gears, shafts, gear boxes, cams,
carriages, camshafts, clutches, brakes, drums, dynamos, feeds,
flywheels, gaskets, pumps, jaws, robotic arms, seals, sockets,
sleeves, valves, wheels, actuators, motors, servomotor, and the
like. Many of the machines and their elements may include
servomotors. The local data collection system 102 may monitor the
motor, the rotary encoder, and the potentiometer of the
servomechanism to provide three-dimensional detail of position,
placement, and progress of industrial processes.
[0332] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from gear drives, powertrains, transfer cases, multispeed
axles, transmissions, direct drives, chain drives, belt-drives,
shaft-drives, magnetic drives, and similar meshing mechanical
drives. In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from fault conditions of industrial machines that may
include overheating, noise, grinding gears, locked gears, excessive
vibration, wobbling, under-inflation, over-inflation, and the like.
Operation faults, maintenance indicators, and interactions from
other machines may cause maintenance or operational issues may
occur during operation, during installation, and during
maintenance. The faults may occur in the mechanisms of the
industrial machines but may also occur in infrastructure that
supports the machine such as its wiring and local installation
platforms. In embodiments, the large industrial machines may face
different types of fault conditions such as overheating, noise,
grinding gears, excessive vibration of machine parts, fan vibration
problems, problems with large industrial machines rotating
parts.
[0333] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
signals from industrial machinery including failures that may be
caused by premature bearing failure that may occur due to
contamination or loss of bearing lubricant. In another example, a
mechanical defect such as misalignment of bearings may occur. Many
factors may contribute to the failure such as metal fatigue,
therefore, the local data collection system 102 may monitor cycles
and local stresses. By way of this example, the platform 100 may
monitor the incorrect operation of machine parts, lack of
maintenance and servicing of parts, corrosion of vital machine
parts, such as couplings or gearboxes, misalignment of machine
parts, and the like. Though the fault occurrences cannot be
completely stopped, many industrial breakdowns may be mitigated to
reduce operational and financial losses. The platform 100 provides
real-time monitoring and predictive maintenance in many industrial
environments wherein it has been shown to present a cost-savings
over regularly-scheduled maintenance processes that replace parts
according to a rigid expiration of time and not actual load and
wear and tear on the element or machine. To that end, the platform
10 may provide reminders of, or perform some, preventive measures
such as adhering to operating manual and mode instructions for
machines, proper lubrication, and maintenance of machine parts,
minimizing or eliminating overrun of machines beyond their defined
capacities, replacement of worn but still functional parts as
needed, properly training the personnel for machine use, and the
like.
[0334] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 to monitor
multiple signals that may be carried by a plurality of physical,
electronic, and symbolic formats or signals. The platform 100 may
employ signal processing including a plurality of mathematical,
statistical, computational, heuristic, and linguistic
representations and processing of signals and a plurality of
operations needed for extraction of useful information from signal
processing operations such as techniques for representation,
modeling, analysis, synthesis, sensing, acquisition, and extraction
of information from signals. In examples, signal processing may be
performed using a plurality of techniques, including but not
limited to transformations, spectral estimations, statistical
operations, probabilistic and stochastic operations, numerical
theory analysis, data mining, and the like. The processing of
various types of signals forms the basis of many electrical or
computational process. As a result, signal processing applies to
almost all disciplines and applications in the industrial
environment such as audio and video processing, image processing,
wireless communications, process control, industrial automation,
financial systems, feature extraction, quality improvements such as
noise reduction, image enhancement, and the like. Signal processing
for images may include pattern recognition for manufacturing
inspections, quality inspection, and automated operational
inspection and maintenance. The platform 100 may employ many
pattern recognition techniques including those that may classify
input data into classes based on key features with the objective of
recognizing patterns or regularities in data. The platform 100 may
also implement pattern recognition processes with machine learning
operations and may be used in applications such as computer vision,
speech and text processing, radar processing, handwriting
recognition, CAD systems, and the like. The platform 100 may employ
supervised classification and unsupervised classification. The
supervised learning classification algorithms may be based to
create classifiers for image or pattern recognition, based on
training data obtained from different object classes. The
unsupervised learning classification algorithms may operate by
finding hidden structures in unlabeled data using advanced analysis
techniques such as segmentation and clustering. For example, some
of the analysis techniques used in unsupervised learning may
include K-means clustering, Gaussian mixture models, Hidden Markov
models, and the like. The algorithms used in supervised and
unsupervised learning methods of pattern recognition enable the use
of pattern recognition in various high precision applications. The
platform 100 may use pattern recognition in face detection related
applications such as security systems, tracking, sports related
applications, fingerprint analysis, medical and forensic
applications, navigation and guidance systems, vehicle tracking,
public infrastructure systems such as transport systems, license
plate monitoring, and the like.
[0335] In embodiments, the platform 100 may include the local data
collection system 102 deployed in the environment 104 using machine
learning to enable derivation-based learning outcomes from
computers without the need to program them. The platform 100 may,
therefore, learn from and make decisions on a set of data, by
making data-driven predictions and adapting according to the set of
data. In embodiments, machine learning may involve performing a
plurality of machine learning tasks by machine learning systems,
such as supervised learning, unsupervised learning, and
reinforcement learning. Supervised learning may include presenting
a set of example inputs and desired outputs to the machine learning
systems. Unsupervised learning may include the learning algorithm
itself structuring its input by methods such as pattern detection
and/or feature learning. Reinforcement learning may include the
machine learning systems performing in a dynamic environment and
then providing feedback about correct and incorrect decisions. In
examples, machine learning may include a plurality of other tasks
based on an output of the machine learning system. In examples, the
tasks may also be classified as machine learning problems such as
classification, regression, clustering, density estimation,
dimensionality reduction, anomaly detection, and the like. In
examples, machine learning may include a plurality of mathematical
and statistical techniques. In examples, the many types of machine
learning algorithms may include decision tree based learning,
association rule learning, deep learning, artificial neural
networks, genetic learning algorithms, inductive logic programming,
support vector machines (SVMs), Bayesian network, reinforcement
learning, representation learning, rule-based machine learning,
sparse dictionary learning, similarity and metric learning,
learning classifier systems (LCS), logistic regression, random
forest, K-Means, gradient boost and adaboost, K-nearest neighbors
(KNN), a priori algorithms, and the like. In embodiments, certain
machine learning algorithms may be used (such as genetic algorithms
defined for solving both constrained and unconstrained optimization
problems that may be based on natural selection, the process that
drives biological evolution). By way of this example, genetic
algorithms may be deployed to solve a variety of optimization
problems that are not well suited for standard optimization
algorithms, including problems in which the objective functions are
discontinuous, not differentiable, stochastic, or highly nonlinear.
In an example, the genetic algorithm may be used to address
problems of mixed integer programming, where some components
restricted to being integer-valued. Genetic algorithms and machine
learning techniques and systems may be used in computational
intelligence systems, computer vision, Natural Language Processing
(NLP), recommender systems, reinforcement learning, building
graphical models, and the like. By way of this example, the machine
learning systems may be used to perform intelligent computing based
control and be responsive to tasks in a wide variety of systems
(such as interactive websites and portals, brain-machine
interfaces, online security and fraud detection systems, medical
applications such as diagnosis and therapy assistance systems,
classification of DNA sequences, and the like). In examples,
machine learning systems may be used in advanced computing
applications (such as online advertising, natural language
processing, robotics, search engines, software engineering, speech
and handwriting recognition, pattern matching, game playing,
computational anatomy, bioinformatics systems and the like). In an
example, machine learning may also be used in financial and
marketing systems (such as for user behavior analytics, online
advertising, economic estimations, financial market analysis, and
the like).
[0336] Additional details are provided below in connection with the
methods, systems, devices, and components depicted in connection
with FIGS. 1 through 6. In embodiments, methods and systems are
disclosed herein for cloud-based, machine pattern recognition based
on fusion of remote, analog industrial sensors. For example, data
streams from vibration, pressure, temperature, accelerometer,
magnetic, electrical field, and other analog sensors may be
multiplexed or otherwise fused, relayed over a network, and fed
into a cloud-based machine learning facility, which may employ one
or more models relating to an operating characteristic of an
industrial machine, an industrial process, or a component or
element thereof. A model may be created by a human who has
experience with the industrial environment and may be associated
with a training data set (such as models created by human analysis
or machine analysis of data that is collected by the sensors in the
environment, or sensors in other similar environments. The learning
machine may then operate on other data, initially using a set of
rules or elements of a model, such as to provide a variety of
outputs, such as classification of data into types, recognition of
certain patterns (such as those indicating the presence of faults,
orthoses indicating operating conditions, such as fuel efficiency,
energy production, or the like). The machine learning facility may
take feedback, such as one or more inputs or measures of success,
such that it may train, or improve, its initial model (such as
improvements by adjusting weights, rules, parameters, or the like,
based on the feedback). For example, a model of fuel consumption by
an industrial machine may include physical model parameters that
characterize weights, motion, resistance, momentum, inertia,
acceleration, and other factors that indicate consumption, and
chemical model parameters (such as those that predict energy
produced and/or consumed e.g., such as through combustion, through
chemical reactions in battery charging and discharging, and the
like). The model may be refined by feeding in data from sensors
disposed in the environment of a machine, in the machine, and the
like, as well as data indicating actual fuel consumption, so that
the machine can provide increasingly accurate, sensor-based,
estimates of fuel consumption and can also provide output that
indicate what changes can be made to increase fuel consumption
(such as changing operation parameters of the machine or changing
other elements of the environment, such as the ambient temperature,
the operation of a nearby machine, or the like). For example, if a
resonance effect between two machines is adversely affecting one of
them, the model may account for this and automatically provide an
output that results in changing the operation of one of the
machines (such as to reduce the resonance, to increase fuel
efficiency of one or both machines). By continuously adjusting
parameters to cause outputs to match actual conditions, the machine
learning facility may self-organize to provide a highly accurate
model of the conditions of an environment (such as for predicting
faults, optimizing operational parameters, and the like). This may
be used to increase fuel efficiency, to reduce wear, to increase
output, to increase operating life, to avoid fault conditions, and
for many other purposes.
[0337] FIG. 14 illustrates components and interactions of a data
collection architecture involving the application of cognitive and
machine learning systems to data collection and processing.
Referring to FIG. 14, a data collection system 102 may be disposed
in an environment (such as an industrial environment where one or
more complex systems, such as electro-mechanical systems and
machines are manufactured, assembled, or operated). The data
collection system 102 may include onboard sensors and may take
input, such as through one or more input interfaces or ports 4008,
from one or more sensors (such as analog or digital sensors of any
type disclosed herein) and from one or more input sources 116 (such
as sources that may be available through Wi-Fi, Bluetooth, NFC, or
other local network connections or over the Internet). Sensors may
be combined and multiplexed (such as with one or more multiplexers
4002). Data may be cached or buffered in a cache/buffer 4022 and
made available to external systems, such as a remote host
processing system 112 as described elsewhere in this disclosure
(which may include an extensive processing architecture 4024,
including any of the elements described in connection with other
embodiments described throughout this disclosure and in the
Figure), though one or more output interfaces and ports 4010 (which
may in embodiments be separate from or the same as the input
interfaces and ports 4008). The data collection system 102 may be
configured to take input from a host processing system 112, such as
input from an analytic system 4018, which may operate on data from
the data collection system 102 and data from other input sources
116 to provide analytic results, which in turn may be provided as a
learning feedback input 4012 to the data collection system, such as
to assist in configuration and operation of the data collection
system 102.
[0338] Combination of inputs (including selection of what sensors
or input sources to turn "on" or "off") may be performed under the
control of machine-based intelligence, such as using a local
cognitive input selection system 4004, an optionally remote
cognitive input selection system 4114, or a combination of the two.
The cognitive input selection systems 4004, 4014 may use
intelligence and machine learning capabilities described elsewhere
in this disclosure, such as using detected conditions (such as
conditions informed by the input sources 116 or sensors), state
information (including state information determined by a machine
state recognition system 4020 that may determine a state), such as
relating to an operational state, an environmental state, a state
within a known process or workflow, a state involving a fault or
diagnostic condition, or many others. This may include optimization
of input selection and configuration based on learning feedback
from the learning feedback system 4012, which may include providing
training data (such as from the host processing system 112 or from
other data collection systems 102 either directly or from the host
112) and may include providing feedback metrics, such as success
metrics calculated within the analytic system 4018 of the host
processing system 112. For example, if a data stream consisting of
a particular combination of sensors and inputs yields positive
results in a given set of conditions (such as providing improved
pattern recognition, improved prediction, improved diagnosis,
improved yield, improved return on investment, improved efficiency,
or the like), then metrics relating to such results from the
analytic system 4018 can be provided via the learning feedback
system 4012 to the cognitive input selection systems 4004, 4014 to
help configure future data collection to select that combination in
those conditions (allowing other input sources to be de-selected,
such as by powering down the other sensors). In embodiments,
selection and de-selection of sensor combinations, under control of
one or more of the cognitive input selection systems 4004, may
occur with automated variation, such as using genetic programming
techniques, based on learning feedback 4012, such as from the
analytic system 4018, effective combinations for a given state or
set of conditions are promoted, and less effective combinations are
demoted, resulting in progressive optimization and adaptation of
the local data collection system to each unique environment. Thus,
an automatically adapting, multi-sensor data collection system is
provided, where cognitive input selection is used (with feedback)
to improve the effectiveness, efficiency, or other performance
parameters of the data collection system within its particular
environment. Performance parameters may relate to overall system
metrics (such as financial yields, process optimization results,
energy production or usage, and the like), analytic metrics (such
as success in recognizing patterns, making predictions, classifying
data, or the like), and local system metrics (such as bandwidth
utilization, storage utilization, power consumption, and the like).
In embodiments, the analytic system 4018, the state system 4020 and
the cognitive input selection system 4114 of a host may take data
from multiple data collection systems 102, such that optimization
(including of input selection) may be undertaken through
coordinated operation of multiple systems 102. For example, the
cognitive input selection system 4114 may understand that if one
data collection system 102 is already collecting vibration data for
an X-axis, the X-axis vibration sensor for the other data
collection system might be turned off, in favor of getting Y-axis
data from the other data collector 102. Thus, through coordinated
collection by the host cognitive input selection system 4114, the
activity of multiple collectors 102, across a host of different
sensors, can provide for a rich data set for the host processing
system 112, without wasting energy, bandwidth, storage space, or
the like. As noted above, optimization may be based on overall
system success metrics, analytic success metrics, and local system
metrics, or a combination of the above.
[0339] Methods and systems are disclosed herein for cloud-based,
machine pattern analysis of state information from multiple
industrial sensors to provide anticipated state information for an
industrial system. In embodiments, machine learning may take
advantage of a state machine, such as tracking states of multiple
analog and/or digital sensors, feeding the states into a pattern
analysis facility, and determining anticipated states of the
industrial system based on historical data about sequences of state
information. For example, where a temperature state of an
industrial machine exceeds a certain threshold and is followed by a
fault condition, such as breaking down of a set of bearings, that
temperature state may be tracked by a pattern recognizer, which may
produce an output data structure indicating an anticipated bearing
fault state (whenever an input state of a high temperature is
recognized). A wide range of measurement values and anticipated
states may be managed by a state machine, relating to temperature,
pressure, vibration, acceleration, momentum, inertia, friction,
heat, heat flux, galvanic states, magnetic field states, electrical
field states, capacitance states, charge and discharge states,
motion, position, and many others. States may comprise combined
states, where a data structure includes a series of states, each of
which is represented by a place in a byte-like data structure. For
example, an industrial machine may be characterized by a genetic
structure, such as one that provides pressure, temperature,
vibration, and acoustic data, the measurement of which takes one
place in the data structure, so that the combined state can be
operated on as a byte-like structure, such as a structure for
compactly characterizing the current combined state of the machine
or environment, or compactly characterizing the anticipated state.
This byte-like structure can be used by a state machine for machine
learning, such as pattern recognition that operates on the
structure to determine patterns that reflect combined effects of
multiple conditions. A wide variety of such structure can be
tracked and used, such as in machine learning, representing various
combinations, of various length, of the different elements that can
be sensed in an industrial environment. In embodiments, byte-like
structures can be used in a genetic programming technique, such as
by substituting different types of data, or data from varying
sources, and tracking outcomes over time, so that one or more
favorable structures emerges based on the success of those
structures when used in real world situations, such as indicating
successful predictions of anticipated states, or achievement of
success operational outcomes, such as increased efficiency,
successful routing of information, achieving increased profits, or
the like. That is, by varying what data types and sources are used
in byte-like structures that are used for machine optimization over
time, a genetic programming-based machine learning facility can
"evolve" a set of data structures, consisting of a favorable mix of
data types (e.g., pressure, temperature, and vibration), from a
favorable mix of data sources (e.g., temperature is derived from
sensor X, while vibration comes from sensor Y), for a given
purpose. Different desired outcomes may result in different data
structures that are best adapted to support effective achievement
of those outcomes over time with application of machine learning
and promotion of structures with favorable results for the desired
outcome in question by genetic programming. The promoted data
structures may provide compact, efficient data for various
activities as described throughout this disclosure, including being
stored in data pools (which may be optimized by storing favorable
data structures that provide the best operational results for a
given environment), being presented in data marketplaces (such as
being presented as the most effective structures for a given
purpose), and the like.
[0340] In embodiments, a platform is provided having cloud-based,
machine pattern analysis of state information from multiple analog
industrial sensors to provide anticipated state information for an
industrial system. In embodiments, the host processing system 112,
such as disposed in the cloud, may include the state system 4020,
which may be used to infer or calculate a current state or to
determine an anticipated future state relating to the data
collection system 102 or some aspect of the environment in which
the data collection system 102 is disposed, such as the state of a
machine, a component, a workflow, a process, an event (e.g.,
whether the event has occurred), an object, a person, a condition,
a function, or the like. Maintaining state information allows the
host processing system 112 to undertake analysis, such as in one or
more analytic systems 4018, to determine contextual information, to
apply semantic and conditional logic, and perform many other
functions as enabled by the processing architecture 4024 described
throughout this disclosure.
[0341] In embodiments, a platform is provided having cloud-based
policy automation engine for IoT, with creation, deployment, and
management of IoT devices. In embodiments, the platform 100
includes (or is integrated with, or included in) the host
processing system 112, such as on a cloud platform, a policy
automation engine 4032 for automating creation, deployment, and
management of policies to IoT devices. Polices, which may include
access policies, network usage policies, storage usage policies,
bandwidth usage policies, device connection policies, security
policies, rule-based policies, role-based polices, and others, may
be required to govern the use of IoT devices. For example, as IoT
devices may have many different network and data communications to
other devices, policies may be needed to indicate to what devices a
given device can connect, what data can be passed on, and what data
can be received. As billions of devices with countless potential
connections are expected to be deployed in the near future, it
becomes impossible for humans to configure policies for IoT devices
on a connection-by-connection basis. Accordingly, an intelligent
policy automation engine 4032 may include cognitive features for
creating, configuring, and managing policies. The policy automation
engine 4032 may consume information about possible policies, such
as from a policy database or library, which may include one or more
public sources of available policies. These may be written in one
or more conventional policy languages or scripts. The policy
automation engine 4032 may apply the policies according to one or
more models, such as based on the characteristics of a given
device, machine, or environment. For example, a large machine, such
as a machine for power generation, may include a policy that only a
verifiably local controller can change certain parameters of the
power generation, thereby avoiding a remote "takeover" by a hacker.
This may be accomplished in turn by automatically finding and
applying security policies that bar connection of the control
infrastructure of the machine to the Internet, by requiring access
authentication, or the like. The policy automation engine 4032 may
include cognitive features, such as varying the application of
policies, the configuration of policies, and the like (such as
features based on state information from the state system 4020).
The policy automation engine 4032 may take feedback, as from the
learning feedback system 4012, such as based on one or more
analytic results from the analytic system 4018, such as based on
overall system results (such as the extent of security breaches,
policy violations, and the like), local results, and analytic
results. By variation and selection based on such feedback, the
policy automation engine 4032 can, over time, learn to
automatically create, deploy, configure, and manage policies across
very large numbers of devices, such as managing policies for
configuration of connections among IoT devices.
[0342] Methods and systems are disclosed herein for on-device
sensor fusion and data storage for industrial IoT devices,
including on-device sensor fusion and data storage for an
industrial IoT device, where data from multiple sensors is
multiplexed at the device for storage of a fused data stream. For
example, pressure and temperature data may be multiplexed into a
data stream that combines pressure and temperature in a time
series, such as in a byte-like structure (where time, pressure, and
temperature are bytes in a data structure, so that pressure and
temperature remain linked in time, without requiring separate
processing of the streams by outside systems), or by adding,
dividing, multiplying, subtracting, or the like, such that the
fused data can be stored on the device. Any of the sensor data
types described throughout this disclosure can be fused in this
manner and stored in a local data pool, in storage, or on an IoT
device, such as a data collector, a component of a machine, or the
like.
[0343] In embodiments, a platform is provided having on-device
sensor fusion and data storage for industrial IoT devices. In
embodiments, a cognitive system is used for a self-organizing
storage system 4028 for the data collection system 102. Sensor
data, and in particular analog sensor data, can consume large
amounts of storage capacity, in particular where a data collector
102 has multiple sensor inputs onboard or from the local
environment. Simply storing all the data indefinitely is not
typically a favorable option, and even transmitting all of the data
may strain bandwidth limitations, exceed bandwidth permissions
(such as exceeding cellular data plan capacity), or the like.
Accordingly, storage strategies are needed. These typically include
capturing only portions of the data (such as snapshots), storing
data for limited time periods, storing portions of the data (such
as intermediate or abstracted forms), and the like. With many
possible selections among these and other options, determining the
correct storage strategy may be highly complex. In embodiments, the
self-organizing storage system 4028 may use a cognitive system,
based on learning feedback 4012, and use various metrics from the
analytic system 4018 or other system of the host cognitive input
selection system 4114, such as overall system metrics, analytic
metrics, and local performance indicators. The self-organizing
storage system 4028 may automatically vary storage parameters, such
as storage locations (including local storage on the data
collection system 102, storage on nearby data collection systems
102 (such as using peer-to-peer organization) and remote storage,
such as network-based storage), storage amounts, storage duration,
type of data stored (including individual sensors or input sources
116, as well as various combined or multiplexed data, such as
selected under the cognitive input selection systems 4004, 4014),
storage type (such as using RAM, Flash, or other short-term memory
versus available hard drive space), storage organization (such as
in raw form, in hierarchies, and the like), and others. Variation
of the parameters may be undertaken with feedback, so that over
time the data collection system 102 adapts its storage of data to
optimize itself to the conditions of its environment, such as a
particular industrial environment, in a way that results in its
storing the data that is needed in the right amounts and of the
right type for availability to users.
[0344] In embodiments, the local cognitive input selection system
4004 may organize fusion of data for various onboard sensors,
external sensors (such as in the local environment) and other input
sources 116 to the local collection system 102 into one or more
fused data streams, such as using the multiplexer 4002 to create
various signals that represent combinations, permutations, mixes,
layers, abstractions, data-metadata combinations, and the like of
the source analog and/or digital data that is handled by the data
collection system 102. The selection of a particular fusion of
sensors may be determined locally by the cognitive input selection
system 4004, such as based on learning feedback from the learning
feedback system 4012, such as various overall system, analytic
system and local system results and metrics. In embodiments, the
system may learn to fuse particular combinations and permutations
of sensors, such as in order to best achieve correct anticipation
of state, as indicated by feedback of the analytic system 4018
regarding its ability to predict future states, such as the various
states handled by the state system 4020. For example, the input
selection system 4004 may indicate selection of a sub-set of
sensors among a larger set of available sensors, and the inputs
from the selected sensors may be combined, such as by placing input
from each of them into a byte of a defined, multi-bit data
structure (such as a combination by taking a signal from each at a
given sampling rate or time and placing the result into the byte
structure, then collecting and processing the bytes over time), by
multiplexing in the multiplexer 4002, such as a combination by
additive mixing of continuous signals, and the like. Any of a wide
range of signal processing and data processing techniques for
combination and fusing may be used, including convolutional
techniques, coercion techniques, transformation techniques, and the
like. The particular fusion in question may be adapted to a given
situation by cognitive learning, such as by having the cognitive
input selection system 4004 learn, based on feedback 4012 from
results (such as feedback conveyed by the analytic system 4018),
such that the local data collection system 102 executes
context-adaptive sensor fusion.
[0345] In embodiments, the analytic system 4018 may apply to any of
a wide range of analytic techniques, including statistical and
econometric techniques (such as linear regression analysis, use
similarity matrices, heat map based techniques, and the like),
reasoning techniques (such as Bayesian reasoning, rule-based
reasoning, inductive reasoning, and the like), iterative techniques
(such as feedback, recursion, feed-forward and other techniques),
signal processing techniques (such as Fourier and other
transforms), pattern recognition techniques (such as Kalman and
other filtering techniques), search techniques, probabilistic
techniques (such as random walks, random forest algorithms, and the
like), simulation techniques (such as random walks, random forest
algorithms, linear optimization and the like), and others. This may
include computation of various statistics or measures. In
embodiments, the analytic system 4018 may be disposed, at least in
part, on a data collection system 102, such that a local analytic
system can calculate one or more measures, such as measures
relating to any of the items noted throughout this disclosure. For
example, measures of efficiency, power utilization, storage
utilization, redundancy, entropy, and other factors may be
calculated onboard, so that the data collection 102 can enable
various cognitive and learning functions noted throughout this
disclosure without dependence on a remote (e.g., cloud-based)
analytic system.
[0346] In embodiments, the host processing system 112, a data
collection system 102, or both, may include, connect to, or
integrate with, a self-organizing networking system 4020, which may
comprise a cognitive system for providing machine-based,
intelligent or organization of network utilization for transport of
data in a data collection system, such as for handling analog and
other sensor data, or other source data, such as among one or more
local data collection systems 102 and a host system 112. This may
include organizing network utilization for source data delivered to
data collection systems, for feedback data, such as analytic data
provided to or via a learning feedback system 4012, data for
supporting a marketplace (such as described in connection with
other embodiments), and output data provided via output interfaces
and ports 4010 from one or more data collection systems 102.
[0347] Methods and systems are disclosed herein for a
self-organizing data marketplace for industrial IoT data, including
where available data elements are organized in the marketplace for
consumption by consumers based on training a self-organizing
facility with a training set and feedback from measures of
marketplace success. A marketplace may be set up initially to make
available data collected from one or more industrial environments,
such as presenting data by type, by source, by environment, by
machine, by one or more patterns, or the like (such as in a menu or
hierarchy). The marketplace may vary the data collected, the
organization of the data, the presentation of the data (including
pushing the data to external sites, providing links, configuring
APIs by which the data may be accessed, and the like), the pricing
of the data, or the like, such as under machine learning, which may
vary different parameters of any of the foregoing. The machine
learning facility may manage all of these parameters by
self-organization, such as by varying parameters over time
(including by varying elements of the data types presented), the
data sourced used to obtain each type of data, the data structures
presented (such as byte-like structures, fused or multiplexed
structures (such as representing multiple sensor types), and
statistical structures (such as representing various mathematical
products of sensor information), among others), the pricing for the
data, where the data is presented, how the data is presented (such
as by APIs, by links, by push messaging, and the like), how the
data is stored, how the data is obtained, and the like. As
parameters are varied, feedback may be obtained as to measures of
success, such as number of views, yield (e.g., price paid) per
access, total yield, per unit profit, aggregate profit, and many
others, and the self-organizing machine learning facility may
promote configurations that improve measures of success and demote
configurations that do not, so that, over time, the marketplace is
progressively configured to present favorable combinations of data
types (e.g., those that provide robust prediction of anticipated
states of particular industrial environments of a given type), from
favorable sources (e.g., those that are reliable, accurate and low
priced), with effective pricing (e.g., pricing that tends to
provide high aggregate profit from the marketplace). The
marketplace may include spiders, web crawlers, and the like to seek
input data sources, such as finding data pools, connected IoT
devices, and the like that publish potentially relevant data. These
may be trained by human users and improved by machine learning in a
manner similar to that described elsewhere in this disclosure.
[0348] In embodiments, a platform is provided having a
self-organizing data marketplace for industrial IoT data. Referring
to FIG. 15, in embodiments, a platform is provided having a
cognitive data marketplace 4102, referred to in some cases as a
self-organizing data marketplace, for data collected by one or more
data collection systems 102 or for data from other sensors or input
sources 116 that are located in various data collection
environments, such as industrial environments. In addition to data
collection systems 102, this may include data collected, handled or
exchanged by IoT devices, such as cameras, monitors, embedded
sensors, mobile devices, diagnostic devices and systems,
instrumentation systems, telematics systems, and the like, such as
for monitoring various parameters and features of machines,
devices, components, parts, operations, functions, conditions,
states, events, workflows and other elements (collectively
encompassed by the term "states") of such environments. Data may
also include metadata about any of the foregoing, such as
describing data, indicating provenance, indicating elements
relating to identity, access, roles, and permissions, providing
summaries or abstractions of data, or otherwise augmenting one or
more items of data to enable further processing, such as for
extraction, transforming, loading, and processing data. Such data
(such term including metadata except where context indicates
otherwise) may be highly valuable to third parties, either as an
individual element (such as the instance where data about the state
of an environment can be used as a condition within a process) or
in the aggregate (such as the instance where collected data,
optionally over many systems and devices in different environments
can be used to develop models of behavior, to train learning
systems, or the like). As billions of IoT devices are deployed,
with countless connections, the amount of available data will
proliferate. To enable access and utilization of data, the
cognitive data marketplace 4102 enables various components,
features, services, and processes for enabling users to supply,
find, consume, and transact in packages of data, such as batches of
data, streams of data (including event streams), data from various
data pools 4120, and the like. In embodiments, the cognitive data
marketplace 4102 may be included in, connected to, or integrated
with, one or more other components of a host processing
architecture 4024 of a host processing system 112, such as a
cloud-based system, as well as to various sensors, input sources
115, data collection systems 102 and the like. The cognitive data
marketplace 4102 may include marketplace interfaces 4108, which may
include one or more supplier interfaces by which data suppliers may
make data available and one more consumer interfaces by which data
may be found and acquired. The consumer interface may include an
interface to a data market search system 4118, which may include
features that enable a user to indicate what types of data a user
wishes to obtain, such as by entering keywords in a natural
language search interface that characterize data or metadata. The
search interface can use various search and filtering techniques,
including keyword matching, collaborative filtering (such as using
known preferences or characteristics of the consumer to match to
similar consumers and the past outcomes of those other consumers),
ranking techniques (such as ranking based on success of past
outcomes according to various metrics, such as those described in
connection with other embodiments in this disclosure). In
embodiments, a supply interface may allow an owner or supplier of
data to supply the data in one or more packages to and through the
cognitive data marketplace 4102, such as packaging batches of data,
streams of data, or the like. The supplier may pre-package data,
such as by providing data from a single input source 116, a single
sensor, and the like, or by providing combinations, permutations,
and the like (such as multiplexed analog data, mixed bytes of data
from multiple sources, results of extraction, loading and
transformation, results of convolution, and the like), as well as
by providing metadata with respect to any of the foregoing.
Packaging may include pricing, such as on a per-batch basis, on a
streaming basis (such as subscription to an event feed or other
feed or stream), on a per item basis, on a revenue share basis, or
other basis. For data involving pricing, a data transaction system
4114 may track orders, delivery, and utilization, including
fulfillment of orders. The transaction system 4114 may include rich
transaction features, including digital rights management, such as
by managing cryptographic keys that govern access control to
purchased data, that govern usage (such as allowing data to be used
for a limited time, in a limited domain, by a limited set of users
or roles, or for a limited purpose). The transaction system 4114
may manage payments, such as by processing credit cards, wire
transfers, debits, and other forms of consideration.
[0349] In embodiments, a cognitive data packaging system 4012 of
the marketplace 4102 may use machine-based intelligence to package
data, such as by automatically configuring packages of data in
batches, streams, pools, or the like. In embodiments, packaging may
be according to one or more rules, models, or parameters, such as
by packaging or aggregating data that is likely to supplement or
complement an existing model. For example, operating data from a
group of similar machines (such as one or more industrial machines
noted throughout this disclosure) may be aggregated together, such
as based on metadata indicating the type of data or by recognizing
features or characteristics in the data stream that indicate the
nature of the data. In embodiments, packaging may occur using
machine learning and cognitive capabilities, such as by learning
what combinations, permutations, mixes, layers, and the like of
input sources 116, sensors, information from data pools 4120 and
information from data collection systems 102 are likely to satisfy
user requirements or result in measures of success. Learning may be
based on learning feedback 4012, such as learning based on measures
determined in an analytic system 4018, such as system performance
measures, data collection measures, analytic measures, and the
like. In embodiments, success measures may be correlated to
marketplace success measures, such as viewing of packages,
engagement with packages, purchase or licensing of packages,
payments made for packages, and the like. Such measures may be
calculated in an analytic system 4018, including associating
particular feedback measures with search terms and other inputs, so
that the cognitive packaging system 4110 can find and configure
packages that are designed to provide increased value to consumers
and increased returns for data suppliers. In embodiments, the
cognitive data packaging system 4110 can automatically vary
packaging, such as using different combinations, permutations,
mixes, and the like, and varying weights applied to given input
sources, sensors, data pools and the like, using learning feedback
4012 to promote favorable packages and de-emphasize less favorable
packages. This may occur using genetic programming and similar
techniques that compare outcomes for different packages. Feedback
may include state information from the state system 4020 (such as
about various operating states, and the like), as well as about
marketplace conditions and states, such as pricing and availability
information for other data sources. Thus, an adaptive cognitive
data packaging system 4110 is provided that automatically adapts to
conditions to provide favorable packages of data for the
marketplace 4102.
[0350] In embodiments, a cognitive data pricing system 4112 may be
provided to set pricing for data packages. In embodiments, the data
pricing system 4112 may use a set of rules, models, or the like,
such as setting pricing based on supply conditions, demand
conditions, pricing of various available sources, and the like. For
example, pricing for a package may be configured to be set based on
the sum of the prices of constituent elements (such as input
sources, sensor data, or the like), or to be set based on a
rule-based discount to the sum of prices for constituent elements,
or the like. Rules and conditional logic may be applied, such as
rules that factor in cost factors (such as bandwidth and network
usage, peak demand factors, scarcity factors, and the like), rules
that factor in utilization parameters (such as the purpose, domain,
user, role, duration, or the like for a package) and many others.
In embodiments, the cognitive data pricing system 4112 may include
fully cognitive, intelligent features, such as using genetic
programming including automatically varying pricing and tracking
feedback on outcomes. Outcomes on which tracking feedback may be
based include various financial yield metrics, utilization metrics
and the like that may be provided by calculating metrics in an
analytic system 4018 on data from the data transaction system
4114.
[0351] Methods and systems are disclosed herein for self-organizing
data pools which may include self-organization of data pools based
on utilization and/or yield metrics, including utilization and/or
yield metrics that are tracked for a plurality of data pools. The
data pools may initially comprise unstructured or loosely
structured pools of data that contain data from industrial
environments, such as sensor data from or about industrial machines
or components. For example, a data pool might take streams of data
from various machines or components in an environment, such as
turbines, compressors, batteries, reactors, engines, motors,
vehicles, pumps, rotors, axles, bearings, valves, and many others,
with the data streams containing analog and/or digital sensor data
(of a wide range of types), data published about operating
conditions, diagnostic and fault data, identifying data for
machines or components, asset tracking data, and many other types
of data. Each stream may have an identifier in the pool, such as
indicating its source, and optionally its type. The data pool may
be accessed by external systems, such as through one or more
interfaces or APIs (e.g., RESTful APIs), or by data integration
elements (such as gateways, brokers, bridges, connectors, or the
like), and the data pool may use similar capabilities to get access
to available data streams. A data pool may be managed by a
self-organizing machine learning facility, which may configure the
data pool, such as by managing what sources are used for the pool,
managing what streams are available, and managing APIs or other
connections into and out of the data pool. The self-organization
may take feedback such as based on measures of success that may
include measures of utilization and yield. The measures of
utilization and yield that may include may account for the cost of
acquiring and/or storing data, as well as the benefits of the pool,
measured either by profit or by other measures that may include
user indications of usefulness, and the like. For example, a
self-organizing data pool might recognize that chemical and
radiation data for an energy production environment are regularly
accessed and extracted, while vibration and temperature data have
not been used, in which case the data pool might automatically
reorganize, such as by ceasing storage of vibration and/or
temperature data, or by obtaining better sources of such data. This
automated reorganization can also apply to data structures, such as
promoting different data types, different data sources, different
data structures, and the like, through progressive iteration and
feedback.
[0352] In embodiments, a platform is provided having
self-organization of data pools based on utilization and/or yield
metrics. In embodiments, the data pools 4020 may be self-organizing
data pools 4020, such as being organized by cognitive capabilities
as described throughout this disclosure. The data pools 4020 may
self-organize in response to learning feedback 4012, such as based
on feedback of measures and results, including calculated in an
analytic system 4018. Organization may include determining what
data or packages of data to store in a pool (such as representing
particular combinations, permutations, aggregations, and the like),
the structure of such data (such as in flat, hierarchical, linked,
or other structures), the duration of storage, the nature of
storage media (such as hard disks, flash memory, SSDs,
network-based storage, or the like), the arrangement of storage
bits, and other parameters. The content and nature of storage may
be varied, such that a data pool 4020 may learn and adapt, such as
based on states of the host system 112, one or more data collection
systems 102, storage environment parameters (such as capacity,
cost, and performance factors), data collection environment
parameters, marketplace parameters, and many others. In
embodiments, pools 4020 may learn and adapt, such as by variation
of the above and other parameters in response to yield metrics
(such as return on investment, optimization of power utilization,
optimization of revenue, and the like).
[0353] Methods and systems are disclosed herein for training AI
models based on industry-specific feedback, including training an
AI model based on industry-specific feedback that reflects a
measure of utilization, yield, or impact, and where the AI model
operates on sensor data from an industrial environment. As noted
above, these models may include operating models for industrial
environments, machines, workflows, models for anticipating states,
models for predicting fault and optimizing maintenance, models for
self-organizing storage (on devices, in data pools and/or in the
cloud), models for optimizing data transport (such as for
optimizing network coding, network-condition-sensitive routing, and
the like), models for optimizing data marketplaces, and many
others.
[0354] In embodiments, a platform is provided having training AI
models based on industry-specific feedback. In embodiments, the
various embodiments of cognitive systems disclosed herein may take
inputs and feedback from industry-specific and domain-specific
sources 116 (such as relating to optimization of specific machines,
devices, components, processes, and the like). Thus, learning and
adaptation of storage organization, network usage, combination of
sensor and input data, data pooling, data packaging, data pricing,
and other features (such as for a marketplace 4102 or for other
purposes of the host processing system 112) may be configured by
learning on the domain-specific feedback measures of a given
environment or application, such as an application involving IoT
devices (such as an industrial environment). This may include
optimization of efficiency (such as in electrical,
electromechanical, magnetic, physical, thermodynamic, chemical and
other processes and systems), optimization of outputs (such as for
production of energy, materials, products, services and other
outputs), prediction, avoidance and mitigation of faults (such as
in the aforementioned systems and processes), optimization of
performance measures (such as returns on investment, yields,
profits, margins, revenues and the like), reduction of costs
(including labor costs, bandwidth costs, data costs, material input
costs, licensing costs, and many others), optimization of benefits
(such as relating to safety, satisfaction, health), optimization of
work flows (such as optimizing time and resource allocation to
processes), and others.
[0355] Methods and systems are disclosed herein for a
self-organized swarm of industrial data collectors, including a
self-organizing swarm of industrial data collectors that organize
among themselves to optimize data collection based on the
capabilities and conditions of the members of the swarm. Each
member of the swarm may be configured with intelligence, and the
ability to coordinate with other members. For example, a member of
the swarm may track information about what data other members are
handling, so that data collection activities, data storage, data
processing, and data publishing can be allocated intelligently
across the swarm, taking into account conditions of the
environment, capabilities of the members of the swarm, operating
parameters, rules (such as from a rules engine that governs the
operation of the swarm), and current conditions of the members. For
example, among four collectors, one that has relatively low current
power levels (such as a low battery), might be temporarily
allocated the role of publishing data, because it may receive a
dose of power from a reader or interrogation device (such as an
RFID reader) when it needs to publish the data. A second collector
with good power levels and robust processing capability might be
assigned more complex functions, such as processing data, fusing
data, organizing the rest of the swarm (including self-organization
under machine learning, such that the swarm is optimized over time,
including by adjusting operating parameters, rules, and the like
based on feedback), and the like. A third collector in the swarm
with robust storage capabilities might be assigned the task of
collecting and storing a category of data, such as vibration sensor
data, that consumes considerable bandwidth. A fourth collector in
the swarm, such as one with lower storage capabilities, might be
assigned the role of collecting data that can usually be discarded,
such as data on current diagnostic conditions, where only data on
faults needs to be maintained and passed along. Members of a swarm
may connect by peer-to-peer relationships by using a member as a
"master" or "hub," or by having them connect in a series or ring,
where each member passes along data (including commands) to the
next, and is aware of the nature of the capabilities and commands
that are suitable for the preceding and/or next member. The swarm
may be used for allocation of storage across it (such as using
memory of each memory as an aggregate data store. In these
examples, the aggregate data store may support a distributed
ledger, which may store transaction data, such as for transactions
involving data collected by the swarm, transactions occurring in
the industrial environment, or the like. In embodiments, the
transaction data may also include data used to manage the swarm,
the environment, or a machine or components thereof. The swarm may
self-organize, either by machine learning capability disposed on
one or more members of the swarm, or based on instructions from an
external machine learning facility, which may optimize storage,
data collection, data processing, data presentation, data
transport, and other functions based on managing parameters that
are relevant to each. The machine learning facility may start with
an initial configuration and vary parameters of the swarm relevant
to any of the foregoing (also including varying the membership of
the swarm), such as iterating based on feedback to the machine
learning facility regarding measures of success (such as
utilization measures, efficiency measures, measures of success in
prediction or anticipation of states, productivity measures, yield
measures, profit measures, and others). Over time, the swarm may be
optimized to a favorable configuration to achieve the desired
measure of success for an owner, operator, or host of an industrial
environment or a machine, component, or process thereof.
[0356] The swarm 4202 may be organized based on a hierarchical
organization (such as where a master data collector 102 organizes
and directs activities of one or more subservient data collectors
102), a collaborative organization (such as where decision-making
for the organization of the swarm 4202 is distributed among the
data collectors 102 (such as using various models for
decision-making, such as voting systems, points systems, least-cost
routing systems, prioritization systems, and the like), and the
like.) In embodiments, one or more of the data collectors 102 may
have mobility capabilities, such as in cases where a data collector
is disposed on or in a mobile robot, drone, mobile submersible, or
the like, so that organization may include the location and
positioning of the data collectors 102. Data collection systems 102
may communicate with each other and with the host processing system
112, including sharing an aggregate allocated storage space
involving storage on or accessible to one or more of the collectors
(which in embodiment may be treated as a unified storage space even
if physically distributed, such as using virtualization
capabilities). Organization may be automated based on one or more
rules, models, conditions, processes, or the like (such as embodied
or executed by conditional logic), and organization may be governed
by policies, such as handled by the policy engine. Rules may be
based on industry, application- and domain-specific objects,
classes, events, workflows, processes, and systems, such as by
setting up the swarm 4202 to collect selected types of data at
designated places and times, such as coordinated with the
foregoing. For example, the swarm 4202 may assign data collectors
102 to serially collect diagnostic, sensor, instrumentation and/or
telematic data from each of a series of machines that execute an
industrial process (such as a robotic manufacturing process), such
as at the time and location of the input to and output from each of
those machines. In embodiments, self-organization may be cognitive,
such as where the swarm varies one or more collection parameters
and adapts the selection of parameters, weights applied to the
parameters, or the like, over time. In examples, this may be in
response to learning and feedback, such as from the learning
feedback system 4012 that may be based on various feedback measures
that may be determined by applying the analytic system 4018 (which
in embodiments may reside on the swarm 4202, the host processing
system 112, or a combination thereof) to data handled by the swarm
4202 or to other elements of the various embodiments disclosed
herein (including marketplace elements and others). Thus, the swarm
4202 may display adaptive behavior, such as adapting to the current
state 4020 or an anticipated state of its environment (accounting
for marketplace behavior), behavior of various objects (such as IoT
devices, machines, components, and systems), processes (including
events, states, workflows, and the like), and other factors at a
given time. Parameters that may be varied in a process of variation
(such as in a neural net, self-organizing map, or the like),
selection, promotion, or the like (such as those enabled by genetic
programming or other AI-based techniques). Parameters that may be
managed, varied, selected and adapted by cognitive, machine
learning may include storage parameters (location, type, duration,
amount, structure and the like across the swarm 4202), network
parameters (such as how the swarm 4202 is organized, such as in
mesh, peer-to-peer, ring, serial, hierarchical and other network
configurations as well as bandwidth utilization, data routing,
network protocol selection, network coding type, and other
networking parameters), security parameters (such as settings for
various security applications and services), location and
positioning parameters (such as routing movement of mobile data
collectors 102 to locations, positioning and orienting collectors
102 and the like relative to points of data acquisition, relative
to each other, and relative to locations where network availability
may be favorable, among others), input selection parameters (such
as input selection among sensors, input sources 116 and the like
for each collector 102 and for the aggregate collection), data
combination parameters (such as those for sensor fusion, input
combination, multiplexing, mixing, layering, convolution, and other
combinations), power parameters (such as parameters based on power
levels and power availability for one or more collectors 102 or
other objects, devices, or the like), states (including anticipated
states and conditions of the swarm 4202, individual collection
systems 102, the host processing system 112 or one or more objects
in an environment), events, and many others. Feedback may be based
on any of the kinds of feedback described herein, such that over
time the swarm may adapt to its current and anticipated situation
to achieve a wide range of desired objectives.
[0357] Methods and systems are disclosed herein for an industrial
IoT distributed ledger, including a distributed ledger supporting
the tracking of transactions executed in an automated data
marketplace for industrial IoT data. A distributed ledger may
distribute storage across devices, using a secure protocol, such as
those used for cryptocurrencies (such as the Blockchain.TM.
protocol used to support the Bitcoin.TM. currency). A ledger or
similar transaction record, which may comprise a structure where
each successive member of a chain stores data for previous
transactions, and a competition can be established to determine
which of alternative data stored data structures is "best" (such as
being most complete), can be stored across data collectors,
industrial machines or components, data pools, data marketplaces,
cloud computing elements, servers, and/or on the IT infrastructure
of an enterprise (such as an owner, operator or host of an
industrial environment or of the systems disclosed herein). The
ledger or transaction may be optimized by machine learning, such as
to provide storage efficiency, security, redundancy, or the
like.
[0358] In embodiments, the cognitive data marketplace 4102 may use
a secure architecture for tracking and resolving transactions, such
as a distributed ledger 4004, wherein transactions in data packages
are tracked in a chained, distributed data structure, such as a
Blockchain.TM., allowing forensic analysis and validation where
individual devices store a portion of the ledger representing
transactions in data packages. The distributed ledger 4004 may be
distributed to IoT devices, to data pools 4020, to data collection
systems 102, and the like, so that transaction information can be
verified without reliance on a single, central repository of
information. The transaction system 4114 may be configured to store
data in the distributed ledger 4004 and to retrieve data from it
(and from constituent devices) in order to resolve transactions.
Thus, a distributed ledger 4004 for handling transactions in data,
such as for packages of IoT data, is provided. In embodiments, the
self-organizing storage system 4028 may be used for optimizing
storage of distributed ledger data, as well as for organizing
storage of packages of data, such as IoT data, that can be
presented in the marketplace 4102.
[0359] Methods and systems are disclosed herein for a
network-sensitive collector, including a network
condition-sensitive, self-organizing, multi-sensor data collector
that can optimize based on bandwidth, quality of service, pricing
and/or other network conditions. Network sensitivity can include
awareness of the price of data transport (such as allowing the
system to pull or push data during off-peak periods or within the
available parameters of paid data plans), the quality of the
network (such as to avoid periods where errors are likely), the
quality of environmental conditions (such as delaying transmission
until signal quality is good, such as when a collector emerges from
a shielded environment, avoiding wasting use of power when seeking
a signal when shielded, such as by large metal structures typically
of industrial environments), and the like.
[0360] Methods and systems are disclosed herein for a remotely
organized universal data collector that can power up and down
sensor interfaces based on need and/or conditions identified in an
industrial data collection environment. For example, interfaces can
recognize what sensors are available and interfaces and/or
processors can be turned on to take input from such sensors,
including hardware interfaces that allow the sensors to plug in to
the data collector, wireless data interfaces (such as where the
collector can ping the sensor, optionally providing some power via
an interrogation signal), and software interfaces (such as for
handling particular types of data). Thus, a collector that is
capable of handling various kinds of data can be configured to
adapt to the particular use in a given environment. In embodiments,
configuration may be automatic or under machine learning, which may
improve configuration by optimizing parameters based on feedback
measures over time.
[0361] Methods and systems are disclosed herein for self-organizing
storage for a multi-sensor data collector, including
self-organizing storage for a multi-sensor data collector for
industrial sensor data. Self-organizing storage may allocate
storage based on application of machine learning, which may improve
storage configuration based on feedback measure over time. Storage
may be optimized by configuring what data types are used (e.g.,
byte-like structures, structures representing fused data from
multiple sensors, structures representing statistics or measures
calculated by applying mathematical functions on data, and the
like), by configuring compression, by configuring data storage
duration, by configuring write strategies (such as by striping data
across multiple storage devices, using protocols where one device
stores instructions for other devices in a chain, and the like),
and by configuring storage hierarchies, such as by providing
pre-calculated intermediate statistics to facilitate more rapid
access to frequently accessed data items. Thus, highly intelligent
storage systems may be configured and optimized, based on feedback,
over time.
[0362] Methods and systems are disclosed herein for self-organizing
network coding for a multi-sensor data network, including
self-organizing network coding for a data network that transports
data from multiple sensors in an industrial data collection
environment. Network coding, including random linear network
coding, can enable highly efficient and reliable transport of large
amounts of data over various kinds of networks. Different network
coding configurations can be selected, based on machine learning,
to optimize network coding and other network transport
characteristics based on network conditions, environmental
conditions, and other factors, such as the nature of the data being
transported, environmental conditions, operating conditions, and
the like (including by training a network coding selection model
over time based on feedback of measures of success, such as any of
the measures described herein).
[0363] In embodiments, a platform is provided having a
self-organizing network coding for multi-sensor data network. A
cognitive system may vary one or more parameters for networking,
such as network type selection (e.g., selecting among available
local, cellular, satellite, Wi-Fi, Bluetooth.TM., NFC, Zigbee.RTM.
and other networks), network selection (such as selecting a
specific network, such as one that is known to have desired
security features), network coding selection (such as selecting a
type of network coding for efficient transport[such as random
linear network coding, fixed coding, and others]), network timing
selection (such as configuring delivery based on network pricing
conditions, traffic and the like), network feature selection (such
as selecting cognitive features, security features, and the like),
network conditions (such as network quality based on current
environmental or operation conditions), network feature selection
(such as enabling available authentication, permission and similar
systems), network protocol selection (such as among HTTP, IP,
TCP/IP, cellular, satellite, serial, packet, streaming, and many
other protocols), and others. Given bandwidth constraints, price
variations, sensitivity to environmental factors, security
concerns, and the like, selecting the optimal network configuration
can be highly complex and situation dependent. The self-organizing
networking system 4030 may vary combinations and permutations of
these parameters while taking input from a learning feedback system
4012 such as using information from the analytic system 4018 about
various measures of outcomes. In the many examples, outcomes may
include overall system measures, analytic success measures, and
local performance indicators. In embodiments, input from a learning
feedback system 4012 may include information from various sensors
and input sources 116, information from the state system 4020 about
states (such as events, environmental conditions, operating
conditions, and many others, or other information) or taking other
inputs. By variation and selection of alternative configurations of
networking parameters in different states, the self-organizing
networking system may find configurations that are well-adapted to
the environment that is being monitored or controlled by the host
system 112, such as the instance where one or more data collection
systems 102 are located and that are well-adapted to emerging
network conditions. Thus, a self-organizing,
network-condition-adaptive data collection system is provided.
[0364] Referring to FIG. 42, a data collection system 102 may have
one or more output interfaces and/or ports 4010. These may include
network ports and connections, application programming interfaces,
and the like. Methods and systems are disclosed herein for a haptic
or multi-sensory user interface, including a wearable haptic or
multi-sensory user interface for an industrial sensor data
collector, with vibration, heat, electrical, and/or sound outputs.
For example, an interface may, based on a data structure configured
to support the interface, be set up to provide a user with input or
feedback, such as based on data from sensors in the environment.
For example, if a fault condition based on a vibration data (such
as resulting from a bearing being worn down, an axle being
misaligned, or a resonance condition between machines) is detected,
it can be presented in a haptic interface by vibration of an
interface, such as shaking a wrist-worn device. Similarly, thermal
data indicating overheating could be presented by warming or
cooling a wearable device, such as while a worker is working on a
machine and cannot necessarily look at a user interface. Similarly,
electrical or magnetic data may be presented by a buzzing, and the
like, such as to indicate presence of an open electrical connection
or wire, etc. That is, a multi-sensory interface can intuitively
help a user (such as a user with a wearable device) get a quick
indication of what is going on in an environment, with the wearable
interface having various modes of interaction that do not require a
user to have eyes on a graphical UI, which may be difficult or
impossible in many industrial environments where a user needs to
keep an eye on the environment.
[0365] In embodiments, a platform is provided having a wearable
haptic user interface for an industrial sensor data collector, with
vibration, heat, electrical, and/or sound outputs. In embodiments,
a haptic user interface 4302 is provided as an output for a data
collection system 102, such as a system for handling and providing
information for vibration, heat, electrical, and/or sound outputs,
such as to one or more components of the data collection system 102
or to another system, such as a wearable device, mobile phone, or
the like. A data collection system 102 may be provided in a form
factor suitable for delivering haptic input to a user, such as
vibration, warming or cooling, buzzing, or the like, such as input
disposed in headgear, an armband, a wristband or watch, a belt, an
item of clothing, a uniform, or the like. In such cases, data
collection systems 102 may be integrated with gear, uniforms,
equipment, or the like worn by users, such as individuals
responsible for operating or monitoring an industrial environment.
In embodiments, signals from various sensors or input sources (or
selective combinations, permutations, mixes, and the like, as
managed by one or more of the cognitive input selection systems
4004, 4014) may trigger haptic feedback. For example, if a nearby
industrial machine is overheating, the haptic interface may alert a
user by warming up, or by sending a signal to another device (such
as a mobile phone) to warm up. If a system is experiencing unusual
vibrations, the haptic interface may vibrate. Thus, through various
forms of haptic input, a data collection system 102 may inform
users of the need to attend to one or more devices, machines, or
other factors (such as those in an industrial environment) without
requiring them to read messages or divert their visual attention
away from the task at hand. The haptic interface, and selection of
what outputs should be provided, may be considered in the cognitive
input selection systems 4004, 4014. For example, user behavior
(such as responses to inputs) may be monitored and analyzed in an
analytic system 4018, and feedback may be provided through the
learning feedback system 4012, so that signals may be provided
based on the right collection or package of sensors and inputs, at
the right time and in the right manner, to optimize the
effectiveness of the haptic system 4202. This may include
rule-based or model-based feedback (such as providing outputs that
correspond in some logical fashion to the source data that is being
conveyed). In embodiments, a cognitive haptic system may be
provided, where selection of inputs or triggers for haptic
feedback, selection of outputs, timing, intensity levels,
durations, and other parameters (or weights applied to them) may be
varied in a process of variation, promotion, and selection (such as
using genetic programming) with feedback based on real world
responses to feedback in actual situations or based on results of
simulation and testing of user behavior. Thus, an adaptive haptic
interface for a data collection system 102 is provided, which may
learn and adapt feedback to satisfy requirements and to optimize
the impact on user behavior, such as for overall system outcomes,
data collection outcomes, analytic outcomes, and the like.
[0366] Methods and systems are disclosed herein for a presentation
layer for AR/VR industrial glasses, where heat map elements are
presented based on patterns and/or parameters in collected data.
Methods and systems are disclosed herein for condition-sensitive,
self-organized tuning of AR/VR interfaces based on feedback metrics
and/or training in industrial environments. In embodiments, any of
the data, measures, and the like described throughout this
disclosure can be presented by visual elements, overlays, and the
like for presentation in the AR/VR interfaces, such as in
industrial glasses, on AR/VR interfaces on smart phones or tablets,
on AR/VR interfaces on data collectors (which may be embodied in
smart phones or tablets), on displays located on machines or
components, and/or on displays located in industrial
environments.
[0367] In embodiments, a platform is provided having heat maps
displaying collected data for AR/VR. In embodiments, a platform is
provided having heat maps 4204 displaying collected data from a
data collection system 102 for providing input to an AR/VR
interface 4208. In embodiments, the heat map interface 4304 is
provided as an output for a data collection system 102, such as for
handling and providing information for visualization of various
sensor data and other data (such as map data, analog sensor data,
and other data), such as to one or more components of the data
collection system 102 or to another system, such as a mobile
device, tablet, dashboard, computer, AR/VR device, or the like. A
data collection system 102 may be provided in a form factor
suitable for delivering visual input to a user, such as the
presentation of a map that includes indicators of levels of analog
and digital sensor data (such as data indicating levels of
rotation, vibration, heating or cooling, pressure, and many other
conditions). In such cases, data collection systems 102 may be
integrated with equipment, or the like that are used by individuals
responsible for operating or monitoring an industrial environment.
In embodiments, signals from various sensors or input sources (or
selective combinations, permutations, mixes, and the like, as
managed by one or more of the cognitive input selection systems
4004, 4014) may provide input data to a heat map. Coordinates may
include real world location coordinates (such as geo-location or
location on a map of an environment), as well as other coordinates,
such as time-based coordinates, frequency-based coordinates, or
other coordinates that allow for representation of analog sensor
signals, digital signals, input source information, and various
combinations, in a map-based visualization, such that colors may
represent varying levels of input along the relevant dimensions.
For example, if a nearby industrial machine is overheating, the
heat map interface may alert a user by showing a machine in bright
red. If a system is experiencing unusual vibrations, the heat map
interface may show a different color for a visual element for the
machine, or it may cause an icon or display element representing
the machine to vibrate in the interface, calling attention to the
element. Clicking, touching, or otherwise interacting with the map
can allow a user to drill down and see underlying sensor or input
data that is used as an input to the heat map display. Thus,
through various forms of display, a data collection system 102 may
inform users of the need to attend to one or more devices,
machines, or other factors, such as those in an industrial
environment, without requiring them to read text-based messages or
input. The heat map interface, and selection of what outputs should
be provided, may be considered in the cognitive input selection
systems 4004, 4014. For example, user behavior (such as responses
to inputs or displays) may be monitored and analyzed in an analytic
system 4018, and feedback may be provided through the learning
feedback system 4012, so that signals may be provided based on the
right collection or package of sensors and inputs, at the right
time and in the right manner, to optimize the effectiveness of the
heat map UI 4304. This may include rule-based or model-based
feedback (such as feedback providing outputs that correspond in
some logical fashion to the source data that is being conveyed). In
embodiments, a cognitive heat map system may be provided, where
selection of inputs or triggers for heat map displays, selection of
outputs, colors, visual representation elements, timing, intensity
levels, durations and other parameters (or weights applied to them)
may be varied in a process of variation, promotion and selection
(such as selection using genetic programming) with feedback based
on real world responses to feedback in actual situations or based
on results of simulation and testing of user behavior. Thus, an
adaptive heat map interface for a data collection system 102, or
data collected thereby 102, or data handled by a host processing
system 112, is provided, which may learn and adapt feedback to
satisfy requirements and to optimize the impact on user behavior
and reaction, such as for overall system outcomes, data collection
outcomes, analytic outcomes, and the like.
[0368] In embodiments, a platform is provided having automatically
tuned AR/VR visualization of data collected by a data collector. In
embodiments, a platform is provided having an automatically tuned
AR/VR visualization system 4308 for visualization of data collected
by a data collection system 102, such as the case where the data
collection system 102 has an AR/VR interface 4208 or provides input
to an AR/VR interface 4308 (such as a mobile phone positioned in a
virtual reality or AR headset, a set of AR glasses, or the like).
In embodiments, the AR/VR system 4308 is provided as an output
interface of a data collection system 102, such as a system for
handling and providing information for visualization of various
sensor data and other data (such as map data, analog sensor data,
and other data), such as to one or more components of the data
collection system 102 or to another system, such as a mobile
device, tablet, dashboard, computer, AR/VR device, or the like. A
data collection system 102 may be provided in a form factor
suitable for delivering AR or VR visual, auditory, or other sensory
input to a user, such as by presenting one or more displays such as
3D-realistic visualizations, objects, maps, camera overlays, or
other overlay elements, maps and the like that include or
correspond to indicators of levels of analog and digital sensor
data (such as data indicating levels of rotation, vibration,
heating or cooling, pressure and many other conditions, to input
sources 116, or the like). In such cases, data collection systems
102 may be integrated with equipment, or the like that are used by
individuals responsible for operating or monitoring an industrial
environment.
[0369] In embodiments, signals from various sensors or input
sources (or selective combinations, permutations, mixes, and the
like as managed by one or more of the cognitive input selection
systems 4004, 4014) may provide input data to populate, configure,
modify, or otherwise determine the AR/VR element. Visual elements
may include a wide range of icons, map elements, menu elements,
sliders, toggles, colors, shapes, sizes, and the like, for
representation of analog sensor signals, digital signals, input
source information, and various combinations. In many examples,
colors, shapes, and sizes of visual overlay elements may represent
varying levels of input along the relevant dimensions for a sensor
or combination of sensors. In further examples, if a nearby
industrial machine is overheating, an AR element may alert a user
by showing an icon representing that type of machine in flashing
red color in a portion of the display of a pair of AR glasses. If a
system is experiencing unusual vibrations, a virtual reality
interface showing visualization of the components of the machine
(such as an overlay of a camera view of the machine with 3D
visualization elements) may show a vibrating component in a
highlighted color, with motion, or the like, to ensure the
component stands out in a virtual reality environment being used to
help a user monitor or service the machine. Clicking, touching,
moving eyes toward, or otherwise interacting with a visual element
in an AR/VR interface may allow a user to drilldown and see
underlying sensor or input data that is used as an input to the
display. Thus, through various forms of display, a data collection
system 102 may inform users of the need to attend to one or more
devices, machines, or other factors (such as in an industrial
environment), without requiring them to read text-based messages or
input or divert attention from the applicable environment (whether
it is a real environment with AR features or a virtual environment,
such as for simulation, training, or the like).
[0370] The AR/VR output interface 4208, and selection and
configuration of what outputs or displays should be provided, may
be handled in the cognitive input selection systems 4004, 4014. For
example, user behavior (such as responses to inputs or displays)
may be monitored and analyzed in an analytic system 4018, and
feedback may be provided through the learning feedback system 4012,
so that AR/VR display signals may be provided based on the right
collection or package of sensors and inputs, at the right time and
in the right manner, to optimize the effectiveness of the AR/VR UI
4308. This may include rule-based or model-based feedback (such as
providing outputs that correspond in some logical fashion to the
source data that is being conveyed). In embodiments, a cognitively
tuned AR/VR interface control system 4308 may be provided, where
selection of inputs or triggers for AR/VR display elements,
selection of outputs (such as colors, visual representation
elements, timing, intensity levels, durations and other parameters
[or weights applied to them]) and other parameters of a VR/AR
environment may be varied in a process of variation, promotion and
selection (such as the use of genetic programming) with feedback
based on real world responses in actual situations or based on
results of simulation and testing of user behavior. Thus, an
adaptive, tuned AR/VR interface for a data collection system 102,
or data collected thereby 102, or data handled by a host processing
system 112, is provided, which may learn and adapt feedback to
satisfy requirements and to optimize the impact on user behavior
and reaction, such as for overall system outcomes, data collection
outcomes, analytic outcomes, and the like.
[0371] As noted above, methods and systems are disclosed herein for
continuous ultrasonic monitoring, including providing continuous
ultrasonic monitoring of rotating elements and bearings of an
energy production facility. Embodiments include using continuous
ultrasonic monitoring of an industrial environment as a source for
a cloud-deployed pattern recognizer. Embodiments include using
continuous ultrasonic monitoring to provide updated state
information to a state machine that is used as an input to a
cloud-deployed pattern recognizer. Embodiments include making
available continuous ultrasonic monitoring information to a user
based on a policy declared in a policy engine. Embodiments include
storing continuous ultrasonic monitoring data with other data in a
fused data structure on an industrial sensor device. Embodiments
include making a stream of continuous ultrasonic monitoring data
from an industrial environment available as a service from a data
marketplace. Embodiments include feeding a stream of continuous
ultrasonic monitoring data into a self-organizing data pool.
Embodiments include training a machine learning model to monitor a
continuous ultrasonic monitoring data stream where the model is
based on a training set created from human analysis of such a data
stream, and is improved based on data collected on performance in
an industrial environment.
[0372] Embodiments include a swarm of data collectors that include
at least one data collector for continuous ultrasonic monitoring of
an industrial environment and at least one other type of data
collector. Embodiments include using a distributed ledger to store
time-series data from continuous ultrasonic monitoring across
multiple devices. Embodiments include collecting a stream of
continuous ultrasonic data in a self-organizing data collector, a
network-sensitive data collector, a remotely organized data
collector, a data collector having self-organized storage and the
like. Embodiments include using self-organizing network coding to
transport a stream of ultrasonic data collected from an industrial
environment. Embodiments include conveying an indicator of a
parameter of a continuously collected ultrasonic data stream via an
interface where the interface is one of a sensory interface of a
wearable device, a heat map visual interface of a wearable device,
an interface that operates with self-organized tuning of the
interface layer, and the like.
[0373] As noted above, methods and systems are disclosed herein for
cloud-based, machine pattern recognition based on fusion of remote
analog industrial sensors. Embodiments include taking input from a
plurality of analog sensors disposed in an industrial environment,
multiplexing the sensors into a multiplexed data stream, feeding
the data stream into a cloud-deployed machine learning facility,
and training a model of the machine learning facility to recognize
a defined pattern associated with the industrial environment.
Embodiments include using a cloud-based pattern recognizer on input
states from a state machine that characterizes states of an
industrial environment. Embodiments include deploying policies by a
policy engine that govern what data can be used by what users and
for what purpose in cloud-based, machine learning. Embodiments
include using a cloud-based platform to identify patterns in data
across a plurality of data pools that contain data published from
industrial sensors. Embodiments include training a model to
identify preferred sensor sets to diagnose a condition of an
industrial environment, where a training set is created by a human
user and the model is improved based on feedback from data
collected about conditions in an industrial environment.
[0374] Embodiments include a swarm of data collectors that is
governed by a policy that is automatically propagated through the
swarm. Embodiments include using a distributed ledger to store
sensor fusion information across multiple devices. Embodiments
include feeding input from a set of data collectors into a
cloud-based pattern recognizer that uses data from multiple sensors
for an industrial environment. The data collectors may be
self-organizing data collectors, network-sensitive data collectors,
remotely organized data collectors, a set of data collectors having
self-organized storage, and the like. Embodiments include a system
for data collection in an industrial environment with
self-organizing network coding for data transport of data fused
from multiple sensors in the environment. Embodiments include
conveying information formed by fusing inputs from multiple sensors
in an industrial data collection system in an interface such as a
multi-sensory interface, a heat map interface, an interface that
operates with self-organized tuning of the interface layer, and the
like.
[0375] As noted above, methods and systems are disclosed herein for
cloud-based, machine pattern analysis of state information from
multiple analog industrial sensors to provide anticipated state
information for an industrial system. Embodiments include using a
policy engine to determine what state information can be used for
cloud-based machine analysis. Embodiments include feeding inputs
from multiple devices that have fused and on-device storage of
multiple sensor streams into a cloud-based pattern recognizer to
determine an anticipated state of an industrial environment.
Embodiments include making an output, such as anticipated state
information, from a cloud-based machine pattern recognizer that
analyzes fused data from remote, analog industrial sensors
available as a data service in a data marketplace. Embodiments
include using a cloud-based pattern recognizer to determine an
anticipated state of an industrial environment based on data
collected from data pools that contain streams of information from
machines in the environment. Embodiments include training a model
to identify preferred state information to diagnose a condition of
an industrial environment, where a training set is created by a
human user and the model is improved based on feedback from data
collected about conditions in an industrial environment.
Embodiments include a swarm of data collectors that feeds a state
machine that maintains current state information for an industrial
environment. Embodiments include using a distributed ledger to
store historical state information for fused sensor states a
self-organizing data collector that feeds a state machine that
maintains current state information for an industrial environment.
Embodiments include a data collector that feeds a state machine
that maintains current state information for an industrial
environment where the data collector may be a network sensitive
data collector, a remotely organized data collector, a data
collector with self-organized storage, and the like. Embodiments
include a system for data collection in an industrial environment
with self-organizing network coding for data transport and
maintains anticipated state information for the environment.
Embodiments include conveying anticipated state information
determined by machine learning in an industrial data collection
system in an interface where the interface may be one or more of a
multisensory interface, a heat map interface an interface that
operates with self-organized tuning of the interface layer, and the
like.
[0376] As noted above, methods and systems are disclosed herein for
a cloud-based policy automation engine for IoT, with creation,
deployment, and management of IoT devices, including a cloud-based
policy automation engine for IoT, enabling creation, deployment and
management of policies that apply to IoT devices. Policies can
relate to data usage to an on-device storage system that stores
fused data from multiple industrial sensors, or what data can be
provided to whom in a self-organizing marketplace for IoT sensor
data. Policies can govern how a self-organizing swarm or data
collector should be organized for a particular industrial
environment, how a network-sensitive data collector should use
network bandwidth for a particular industrial environment, how a
remotely organized data collector should collect, and make
available, data relating to a specified industrial environment, or
how a data collector should self-organize storage for a particular
industrial environment. Policies can be deployed across a set of
self-organizing pools of data that contain data streamed from
industrial sensing devices to govern use of data from the pools or
stored on a device that governs use of storage capabilities of the
device for a distributed ledger. Embodiments include training a
model to determine what policies should be deployed in an
industrial data collection system. Embodiments include a system for
data collection in an industrial environment with a policy engine
for deploying policy within the system and, optionally,
self-organizing network coding for data transport, wherein in
certain embodiments, a policy applies to how data will be presented
in a multi-sensory interface, a heat map visual interface, or in an
interface that operates with self-organized tuning of the interface
layer.
[0377] As noted above, methods and systems are disclosed herein for
on-device sensor fusion and data storage for industrial IoT
devices, such as an industrial data collector, including
self-organizing, remotely organized, or network-sensitive
industrial data collectors, where data from multiple sensors is
multiplexed at the device for storage of a fused data stream.
Embodiments include a self-organizing marketplace that presents
fused sensor data that is extracted from on-device storage of IoT
devices. Embodiments include streaming fused sensor information
from multiple industrial sensors and from an on-device data storage
facility to a data pool. Embodiments include training a model to
determine what data should be stored on a device in a data
collection environment. Embodiments include a self-organizing swarm
of industrial data collectors that organize among themselves to
optimize data collection, where at least some of the data
collectors have on-device storage of fused data from multiple
sensors. Embodiments include storing distributed ledger information
with fused sensor information on an industrial IoT device.
Embodiments include a system for data collection with on-device
sensor fusion, such as of industrial sensor data and, optionally,
self-organizing network coding for data transport, where data
structures are stored to support alternative, multi-sensory modes
of presentation, visual heat map modes of presentation, and/or an
interface that operates with self-organized tuning of the interface
layer.
[0378] As noted above, methods and systems are disclosed herein for
a self-organizing data marketplace for industrial IoT data, where
available data elements are organized in the marketplace for
consumption by consumers based on training a self-organizing
facility with a training set and feedback from measures of
marketplace success. Embodiments include organizing a set of data
pools in a self-organizing data marketplace based on utilization
metrics for the data pools. Embodiments include training a model to
determine pricing for data in a data marketplace. The data
marketplace is fed with data streams from a self-organizing swarm
of industrial data collectors, a set of industrial data collectors
that have self-organizing storage, or self-organizing,
network-sensitive, or remotely organized industrial data
collectors. Embodiments include using a distributed ledger to store
transactional data for a self-organizing marketplace for industrial
IoT data. Embodiments include using self-organizing network coding
for data transport to a marketplace for sensor data collected in
industrial environments. Embodiments include providing a library of
data structures suitable for presenting data in alternative,
multi-sensory interface modes in a data marketplace, in heat map
visualization, and/or in interfaces that operate with
self-organized tuning of the interface layer.
[0379] As noted above, methods and systems are disclosed herein for
self-organizing data pools such as those that self-organize based
on utilization and/or yield metrics that may be tracked for a
plurality of data pools. In embodiments, the pools contain data
from self-organizing data collectors. Embodiments include training
a model to present the most valuable data in a data marketplace,
where training is based on industry-specific measures of success.
Embodiments include populating a set of self-organizing data pools
with data from a self-organizing swarm of data collectors.
Embodiments include using a distributed ledger to store
transactional information for data that is deployed in data pools,
where the distributed ledger is distributed across the data pools.
Embodiments include populating a set of self-organizing data pools
with data from a set of network-sensitive or remotely organized
data collectors or a set of data collectors having self-organizing
storage. Embodiments include a system for data collection in an
industrial environment with self-organizing pools for data storage
and self-organizing network coding for data transport, such as a
system that includes a source data structure for supporting data
presentation in a multi-sensory interface, in a heat map interface,
and/or in an interface that operates with self-organized tuning of
the interface layer.
[0380] As noted above, methods and systems are disclosed herein for
training AI models based on industry-specific feedback, such as
that reflects a measure of utilization, yield, or impact, where the
AI model operates on sensor data from an industrial environment.
Embodiments include training a swarm of data collectors, or data
collectors, such as remotely organized, self-organizing, or
network-sensitive data collectors, based on industry-specific
feedback or network and industrial conditions in an industrial
environment, such as to configure storage. Embodiments include
training an AI model to identify and use available storage
locations in an industrial environment for storing distributed
ledger information. Embodiments include training a remote organizer
for a remotely organized data collector based on industry-specific
feedback measures. Embodiments include a system for data collection
in an industrial environment with cloud-based training of a network
coding model for organizing network coding for data transport or a
facility that manages presentation of data in a multi-sensory
interface, in a heat map interface, and/or in an interface that
operates with self-organized tuning of the interface layer.
[0381] As noted above, methods and systems are disclosed herein for
a self-organized swarm of industrial data collectors that organize
among themselves to optimize data collection based on the
capabilities and conditions of the members of the swarm.
Embodiments include deploying distributed ledger data structures
across a swarm of data. Data collectors may be network-sensitive
data collectors configured for remote organization or have
self-organizing storage. Systems for data collection in an
industrial environment with a swarm can include a self-organizing
network coding for data transport. Systems include swarms that
relay information for use in a multi-sensory interface, in a heat
map interface, and/or in an interface that operates with
self-organized tuning of the interface layer.
[0382] As noted above, methods and systems are disclosed herein for
an industrial IoT distributed ledger, including a distributed
ledger supporting the tracking of transactions executed in an
automated data marketplace for industrial IoT data. Embodiments
include a self-organizing data collector that is configured to
distribute collected information to a distributed ledger.
Embodiments include a network-sensitive data collector that is
configured to distribute collected information to a distributed
ledger based on network conditions. Embodiments include a remotely
organized data collector that is configured to distribute collected
information to a distributed ledger based on intelligent, remote
management of the distribution. Embodiments include a data
collector with self-organizing local storage that is configured to
distribute collected information to a distributed ledger.
Embodiments include a system for data collection in an industrial
environment using a distributed ledger for data storage and
self-organizing network coding for data transport, wherein data
storage is of a data structure supporting a haptic interface for
data presentation, a heat map interface for data presentation,
and/or an interface that operates with self-organized tuning of the
interface layer.
[0383] As noted above, methods and systems are disclosed herein for
a self-organizing collector, including a self-organizing,
multi-sensor data collector that can optimize data collection,
power and/or yield based on conditions in its environment, and is
optionally responsive to remote organization. Embodiments include a
self-organizing data collector that organizes at least in part
based on network conditions. Embodiments include a self-organizing
data collector with self-organizing storage for data collected in
an industrial data collection environment. Embodiments include a
system for data collection in an industrial environment with
self-organizing data collection and self-organizing network coding
for data transport. Embodiments include a system for data
collection in an industrial environment with a self-organizing data
collector that feeds a data structure supporting a haptic or
multi-sensory wearable interface for data presentation, a heat map
interface for data presentation, and/or an interface that operates
with self-organized tuning of the interface layer.
[0384] As noted above, methods and systems are disclosed herein for
a network-sensitive collector, including a network
condition-sensitive, self-organizing, multi-sensor data collector
that can optimize based on bandwidth, quality of service, pricing,
and/or other network conditions. Embodiments include a remotely
organized, network condition-sensitive universal data collector
that can power up and down sensor interfaces based on need and/or
conditions identified in an industrial data collection environment,
including network conditions. Embodiments include a
network-condition sensitive data collector with self-organizing
storage for data collected in an industrial data collection
environment. Embodiments include a network-condition sensitive data
collector with self-organizing network coding for data transport in
an industrial data collection environment. Embodiments include a
system for data collection in an industrial environment with a
network-sensitive data collector that relays a data structure
supporting a haptic wearable interface for data presentation, a
heat map interface for data presentation, and/or an interface that
operates with self-organized tuning of the interface layer.
[0385] As noted above, methods and systems are disclosed herein for
a remotely organized universal data collector that can power up and
down sensor interfaces based on need and/or conditions identified
in an industrial data collection environment. Embodiments include a
remotely organized universal data collector with self-organizing
storage for data collected in an industrial data collection
environment. Embodiments include a system for data collection in an
industrial environment with remote control of data collection and
self-organizing network coding for data transport. Embodiments
include a remotely organized data collector for storing sensor data
and delivering instructions for use of the data in a haptic or
multi-sensory wearable interface, in a heat map visual interface,
and/or in an interface that operates with self-organized tuning of
the interface layer.
[0386] As noted above, methods and systems are disclosed herein for
self-organizing storage for a multi-sensor data collector,
including self-organizing storage for a multi-sensor data collector
for industrial sensor data. Embodiments include a system for data
collection in an industrial environment with self-organizing data
storage and self-organizing network coding for data transport.
Embodiments include a data collector with self-organizing storage
for storing sensor data and instructions for translating the data
for use in a haptic wearable interface, in a heat map presentation
interface, and/or in an interface that operates with self-organized
tuning of the interface layer.
[0387] As noted above, methods and systems are disclosed herein for
self-organizing network coding for a multi-sensor data network,
including self-organizing network coding for a data network that
transports data from multiple sensors in an industrial data
collection environment. The system includes a data structure
supporting a haptic wearable interface for data presentation, a
heat map interface for data presentation, and/or self-organized
tuning of an interface layer for data presentation.
[0388] As noted above, methods and systems are disclosed herein for
a haptic or multi-sensory user interface, including a wearable
haptic or multi-sensory user interface for an industrial sensor
data collector, with vibration, heat, electrical, and/or sound
outputs. Embodiments include a wearable haptic user interface for
conveying industrial state information from a data collector, with
vibration, heat, electrical, and/or sound outputs. The wearable
also has a visual presentation layer for presenting a heat map that
indicates a parameter of the data. Embodiments include
condition-sensitive, self-organized tuning of AR/VR interfaces and
multi-sensory interfaces based on feedback metrics and/or training
in industrial environments.
[0389] As noted above, methods and systems are disclosed herein for
a presentation layer for AR/VR industrial glasses, where heat map
elements are presented based on patterns and/or parameters in
collected data. Embodiments include condition-sensitive,
self-organized tuning of a heat map AR/VR interface based on
feedback metrics and/or training in industrial environments. As
noted above, methods and systems are disclosed herein for
condition-sensitive, self-organized tuning of AR/VR interfaces
based on feedback metrics and/or training in industrial
environments.
[0390] The following illustrative clauses describe certain
embodiments of the present disclosure. The data collection system
mentioned in the following disclosure may be a local data
collection system 102, a host processing system 112 (e.g., using a
cloud platform), or a combination of a local system and a host
system. In embodiments, a data collection system or data collection
and processing system is provided having the use of an analog
crosspoint switch for collecting data having variable groups of
analog sensor inputs and, in some embodiments, having IP
front-end-end signal conditioning on a multiplexer for improved
signal-to-noise ratio, multiplexer continuous monitoring alarming
features, the use of distributed CPLD chips with a dedicated bus
for logic control of multiple MUX and data acquisition sections,
high-amperage input capability using solid state relays and design
topology, power-down capability of at least one of an analog sensor
channel and of a component board, unique electrostatic protection
for trigger and vibration inputs, and/or precise voltage reference
for A/D zero reference.
[0391] In embodiments, a data collection and processing system is
provided having the use of an analog crosspoint switch for
collecting data having variable groups of analog sensor inputs and
having a phase-lock loop band-pass tracking filter for obtaining
slow-speed RPMs and phase information, digital derivation of phase
relative to input and trigger channels using on-board timers, a
peak-detector for auto-scaling that is routed into a separate
analog-to-digital converter for peak detection, the routing of a
trigger channel that is either raw or buffered into other analog
channels, the use of higher input oversampling for delta-sigma A/D
for lower sampling rate outputs to minimize AA filter requirements,
and/or the use of a CPLD as a clock-divider for a delta-sigma
analog-to-digital converter to achieve lower sampling rates without
the need for digital resampling.
[0392] In embodiments, a data collection and processing system is
provided having the use of an analog crosspoint switch for
collecting data having variable groups of analog sensor inputs and
having long blocks of data at a high-sampling rate, as opposed to
multiple sets of data taken at different sampling rates, storage of
calibration data with a maintenance history on-board card set, a
rapid route creation capability using hierarchical templates,
intelligent management of data collection bands, and/or a neural
net expert system using intelligent management of data collection
bands.
[0393] In embodiments, a data collection and processing system is
provided having the use of an analog crosspoint switch for
collecting data having variable groups of analog sensor inputs and
having use of a database hierarchy in sensor data analysis, an
expert system GUI graphical approach to defining intelligent data
collection bands and diagnoses for the expert system, a graphical
approach for back-calculation definition, proposed bearing analysis
methods, torsional vibration detection/analysis utilizing
transitory signal analysis, and/or improved integration using both
analog and digital methods.
[0394] In embodiments, a data collection and processing system is
provided having the use of an analog crosspoint switch for
collecting data having variable groups of analog sensor inputs and
having adaptive scheduling techniques for continuous monitoring of
analog data in a local environment, data acquisition parking
features, a self-sufficient data acquisition box, SD card storage,
extended onboard statistical capabilities for continuous
monitoring, the use of ambient, local and vibration noise for
prediction, smart route changes based on incoming data or alarms to
enable simultaneous dynamic data for analysis or correlation, smart
ODS and transfer functions, a hierarchical multiplexer,
identification of sensor overload, and/or RF identification and an
inclinometer.
[0395] In embodiments, a data collection and processing system is
provided having the use of an analog crosspoint switch for
collecting data having variable groups of analog sensor inputs and
having continuous ultrasonic monitoring, cloud-based, machine
pattern recognition based on the fusion of remote, analog
industrial sensors, cloud-based, machine pattern analysis of state
information from multiple analog industrial sensors to provide
anticipated state information for an industrial system, cloud-based
policy automation engine for IoT, with creation, deployment, and
management of IoT devices, on-device sensor fusion and data storage
for industrial IoT devices, a self-organizing data marketplace for
industrial IoT data, self-organization of data pools based on
utilization and/or yield metrics, training AI models based on
industry-specific feedback, a self-organized swarm of industrial
data collectors, an IoT distributed ledger, a self-organizing
collector, a network-sensitive collector, a remotely organized
collector, a self-organizing storage for a multi-sensor data
collector, a self-organizing network coding for multi-sensor data
network, a wearable haptic user interface for an industrial sensor
data collector, with vibration, heat, electrical, and/or sound
outputs, heat maps displaying collected data for AR/VR, and/or
automatically tuned AR/VR visualization of data collected by a data
collector.
[0396] In embodiments, a data collection and processing system is
provided having IP front-end signal conditioning on a multiplexer
for improved signal-to-noise ratio. In embodiments, a data
collection and processing system is provided having IP front-end
signal conditioning on a multiplexer for improved signal-to-noise
ratio and having at least one of: multiplexer continuous monitoring
alarming features; IP front-end signal conditioning on a
multiplexer for improved signal-to-noise ratio; the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections. In embodiments, a data
collection and processing system is provided having IP front-end
signal conditioning on a multiplexer for improved signal-to-noise
ratio and having at least one of: high-amperage input capability
using solid state relays and design topology; power-down capability
of at least one analog sensor channel and of a component board;
unique electrostatic protection for trigger and vibration inputs;
precise voltage reference for A/D zero reference; and a phase-lock
loop band-pass tracking filter for obtaining slow-speed RPMs and
phase information. In embodiments, a data collection and processing
system is provided having IP front-end signal conditioning on a
multiplexer for improved signal-to-noise ratio and having at least
one of: digital derivation of phase relative to input and trigger
channels using on-board timers; a peak-detector for auto-scaling
that is routed into a separate analog-to-digital converter for peak
detection; routing of a trigger channel that is either raw or
buffered into other analog channels; the use of higher input
oversampling for delta-sigma A/D for lower sampling rate outputs to
minimize AA filter requirements; and the use of a CPLD as a
clock-divider for a delta-sigma analog-to-digital converter to
achieve lower sampling rates without the need for digital
resampling. In embodiments, a data collection and processing system
is provided having IP front-end signal conditioning on a
multiplexer for improved signal-to-noise ratio and having at least
one of: long blocks of data at a high-sampling rate as opposed to
multiple sets of data taken at different sampling rates; storage of
calibration data with a maintenance history on-board card set; a
rapid route creation capability using hierarchical templates;
intelligent management of data collection bands; and a neural net
expert system using intelligent management of data collection
bands. In embodiments, a data collection and processing system is
provided having IP front-end signal conditioning on a multiplexer
for improved signal-to-noise ratio and having at least one of: use
of a database hierarchy in sensor data analysis; an expert system
GUI graphical approach to defining intelligent data collection
bands and diagnoses for the expert system; and a graphical approach
for back-calculation definition. In embodiments, a data collection
and processing system is provided having IP front-end signal
conditioning on a multiplexer for improved signal-to-noise ratio
and having at least one of: proposed bearing analysis methods;
torsional vibration detection/analysis utilizing transitory signal;
improved integration using both analog and digital methods;
adaptive scheduling techniques for continuous monitoring of analog
data in a local environment; data acquisition parking features; a
self-sufficient data acquisition box; and SD card storage. In
embodiments, a data collection and processing system is provided
having IP front-end signal conditioning on a multiplexer for
improved signal-to-noise ratio and having at least one of: extended
onboard statistical capabilities for continuous monitoring; the use
of ambient, local, and vibration noise for prediction; smart route
changes based on incoming data or alarms to enable simultaneous
dynamic data for analysis or correlation; smart ODS and transfer
functions; and a hierarchical multiplexer. In embodiments, a data
collection and processing system is provided having IP front-end
signal conditioning on a multiplexer for improved signal-to-noise
ratio and having at least one of: identification of sensor
overload; RF identification and an inclinometer; continuous
ultrasonic monitoring; machine pattern recognition based on the
fusion of remote, analog industrial sensors; and cloud-based,
machine pattern analysis of state information from multiple analog
industrial sensors to provide anticipated state information for an
industrial system. In embodiments, a data collection and processing
system is provided having IP front-end signal conditioning on a
multiplexer for improved signal-to-noise ratio and having at least
one of: cloud-based policy automation engine for IoT, with
creation, deployment, and management of IoT devices; on-device
sensor fusion and data storage for industrial IoT devices; a
self-organizing data marketplace for industrial IoT data; and
self-organization of data pools based on utilization and/or yield
metrics. In embodiments, a data collection and processing system is
provided having IP front-end signal conditioning on a multiplexer
for improved signal-to-noise ratio and having at least one of:
training AI models based on industry-specific feedback; a
self-organized swarm of industrial data collectors; an IoT
distributed ledger; a self-organizing collector; and a
network-sensitive collector. In embodiments, a data collection and
processing system is provided having IP front-end signal
conditioning on a multiplexer for improved signal-to-noise ratio
and having at least one of: a remotely organized collector; a
self-organizing storage for a multi-sensor data collector; a
self-organizing network coding for multi-sensor data network; a
wearable haptic user interface for an industrial sensor data
collector, with vibration, heat, electrical, and/or sound outputs;
heat maps displaying collected data for AR/VR; and automatically
tuned AR/VR visualization of data collected by a data
collector.
[0397] In embodiments, a data collection and processing system is
provided having multiplexer continuous monitoring alarming
features. In embodiments, a data collection and processing system
is provided having multiplexer continuous monitoring alarming
features and having at least one of: the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections; high-amperage input capability using solid
state relays and design topology; power-down capability of at least
one of an analog sensor channel and/or of a component board; unique
electrostatic protection for trigger and vibration inputs; and
precise voltage reference for A/D zero reference. In embodiments, a
data collection and processing system is provided having
multiplexer continuous monitoring alarming features and having at
least one of: a phase-lock loop band-pass tracking filter for
obtaining slow-speed RPMs and phase information; digital derivation
of phase relative to input and trigger channels using on-board
timers; a peak-detector for auto-scaling that is routed into a
separate analog-to-digital converter for peak detection; and
routing of a trigger channel that is either raw or buffered into
other analog channels. In embodiments, a data collection and
processing system is provided having multiplexer continuous
monitoring alarming features and having at least one of: the use of
higher input oversampling for delta-sigma A/D for lower sampling
rate outputs to minimize AA filter requirements; the use of a CPLD
as a clock-divider for a delta-sigma analog-to-digital converter to
achieve lower sampling rates without the need for digital
resampling; long blocks of data at a high-sampling rate as opposed
to multiple sets of data taken at different sampling rates; storage
of calibration data with a maintenance history on-board card set;
and a rapid route creation capability using hierarchical templates.
In embodiments, a data collection and processing system is provided
having multiplexer continuous monitoring alarming features and
having at least one of: intelligent management of data collection
bands; a neural net expert system using intelligent management of
data collection bands; use of a database hierarchy in sensor data
analysis; and an expert system GUI graphical approach to defining
intelligent data collection bands and diagnoses for the expert
system. In embodiments, a data collection and processing system is
provided having multiplexer continuous monitoring alarming features
and having at least one of: a graphical approach for
back-calculation definition; proposed bearing analysis methods;
torsional vibration detection/analysis utilizing transitory signal
analysis; and improved integration using both analog and digital
methods. In embodiments, a data collection and processing system is
provided having multiplexer continuous monitoring alarming features
and having at least one of adaptive scheduling techniques for
continuous monitoring of analog data in a local environment; data
acquisition parking features; a self-sufficient data acquisition
box; and SD card storage. In embodiments, a data collection and
processing system is provided having multiplexer continuous
monitoring alarming features and having at least one of: extended
onboard statistical capabilities for continuous monitoring; the use
of ambient, local and vibration noise for prediction; smart route
changes based on incoming data or alarms to enable simultaneous
dynamic data for analysis or correlation; and smart ODS and
transfer functions. In embodiments, a data collection and
processing system is provided having multiplexer continuous
monitoring alarming features and having at least one of: a
hierarchical multiplexer; identification of sensor overload; RF
identification, and an inclinometer; cloud-based, machine pattern
recognition based on the fusion of remote, analog industrial
sensors; and machine pattern analysis of state information from
multiple analog industrial sensors to provide anticipated state
information for an industrial system. In embodiments, a data
collection and processing system is provided having multiplexer
continuous monitoring alarming features and having at least one of:
cloud-based policy automation engine for IoT, with creation,
deployment, and management of IoT devices; on-device sensor fusion
and data storage for industrial IoT devices; a self-organizing data
marketplace for industrial IoT data; self-organization of data
pools based on utilization and/or yield metrics; and training AI
models based on industry-specific feedback. In embodiments, a data
collection and processing system is provided having multiplexer
continuous monitoring alarming features and having at least one of:
a self-organized swarm of industrial data collectors; an IoT
distributed ledger; a self-organizing collector; a
network-sensitive collector; and a remotely organized collector. In
embodiments, a data collection and processing system is provided
having multiplexer continuous monitoring alarming features and
having at least one of: a self-organizing storage for a
multi-sensor data collector; and a self-organizing network coding
for multi-sensor data network. In embodiments, a data collection
and processing system is provided having multiplexer continuous
monitoring alarming features and having at least one of: a wearable
haptic user interface for an industrial sensor data collector, with
vibration, heat, electrical, and/or sound outputs; heat maps
displaying collected data for AR/VR; and automatically tuned AR/VR
visualization of data collected by a data collector.
[0398] In embodiments, a data collection and processing system is
provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition
sections. In embodiments, a data collection and processing system
is provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having high-amperage input capability using solid state relays
and design topology. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having power-down capability of at least
one of an analog sensor channel and of a component board. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having unique electrostatic protection for trigger and vibration
inputs. In embodiments, a data collection and processing system is
provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having precise voltage reference for A/D zero reference. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having a phase-lock loop band-pass tracking filter for obtaining
slow-speed RPMs and phase information. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having digital
derivation of phase relative to input and trigger channels using
on-board timers. In embodiments, a data collection and processing
system is provided having the use of distributed CPLD chips with
dedicated bus for logic control of multiple MUX and data
acquisition sections and having a peak-detector for auto-scaling
that is routed into a separate analog-to-digital converter for peak
detection. In embodiments, a data collection and processing system
is provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having routing of a trigger channel that is either raw or
buffered into other analog channels. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having the use of
higher input oversampling for delta-sigma A/D for lower sampling
rate outputs to minimize AA filter requirements. In embodiments, a
data collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having the use of a
CPLD as a clock-divider for a delta-sigma analog-to-digital
converter to achieve lower sampling rates without the need for
digital resampling. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having long blocks of data at a
high-sampling rate as opposed to multiple sets of data taken at
different sampling rates. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having storage of calibration data with a
maintenance history on-board card set. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having a rapid route
creation capability using hierarchical templates. In embodiments, a
data collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having intelligent
management of data collection bands. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having a neural net
expert system using intelligent management of data collection
bands. In embodiments, a data collection and processing system is
provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having use of a database hierarchy in sensor data analysis. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having an expert system GUI graphical approach to defining
intelligent data collection bands and diagnoses for the expert
system. In embodiments, a data collection and processing system is
provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having a graphical approach for back-calculation definition. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having proposed bearing analysis methods. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having torsional
vibration detection/analysis utilizing transitory signal analysis.
In embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having improved integration using both analog and digital methods.
In embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having adaptive scheduling techniques for continuous monitoring of
analog data in a local environment. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having data
acquisition parking features. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having a self-sufficient data acquisition
box. In embodiments, a data collection and processing system is
provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having SD card storage. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having extended onboard statistical
capabilities for continuous monitoring. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having the use of
ambient, local and vibration noise for prediction. In embodiments,
a data collection and processing system is provided having the use
of distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having smart route
changes based on incoming data or alarms to enable simultaneous
dynamic data for analysis or correlation. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having smart ODS and
transfer functions. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having a hierarchical multiplexer. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having identification of sensor overload. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having RF
identification and an inclinometer. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having continuous
ultrasonic monitoring. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having cloud-based, machine pattern
recognition based on fusion of remote, analog industrial sensors.
In embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having cloud-based, machine pattern analysis of state information
from multiple analog industrial sensors to provide anticipated
state information for an industrial system. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having cloud-based
policy automation engine for IoT, with creation, deployment, and
management of IoT devices. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having on-device sensor fusion and data
storage for industrial IoT devices. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having a
self-organizing data marketplace for industrial IoT data. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having self-organization of data pools based on utilization and/or
yield metrics. In embodiments, a data collection and processing
system is provided having the use of distributed CPLD chips with
dedicated bus for logic control of multiple MUX and data
acquisition sections and having training AI models based on
industry-specific feedback. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having a self-organized swarm of
industrial data collectors. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having an IoT distributed ledger. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having a self-organizing collector. In embodiments, a data
collection and processing system is provided having the use of
distributed CPLD chips with dedicated bus for logic control of
multiple MUX and data acquisition sections and having a
network-sensitive collector. In embodiments, a data collection and
processing system is provided having the use of distributed CPLD
chips with dedicated bus for logic control of multiple MUX and data
acquisition sections and having a remotely organized collector. In
embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having a self-organizing storage for a multi-sensor data collector.
In embodiments, a data collection and processing system is provided
having the use of distributed CPLD chips with dedicated bus for
logic control of multiple MUX and data acquisition sections and
having a self-organizing network coding for multi-sensor data
network. In embodiments, a data collection and processing system is
provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having a wearable haptic user interface for an industrial
sensor data collector, with vibration, heat, electrical, and/or
sound outputs. In embodiments, a data collection and processing
system is provided having the use of distributed CPLD chips with
dedicated bus for logic control of multiple MUX and data
acquisition sections and having heat maps displaying collected data
for AR/VR. In embodiments, a data collection and processing system
is provided having the use of distributed CPLD chips with dedicated
bus for logic control of multiple MUX and data acquisition sections
and having automatically tuned AR/VR visualization of data
collected by a data collector.
[0399] In embodiments, a data collection and processing system is
provided having one or more of high-amperage input capability using
solid state relays and design topology, power-down capability of at
least one of an analog sensor channel and of a component board,
unique electrostatic protection for trigger and vibration inputs,
precise voltage reference for A/D zero reference, a phase-lock loop
band-pass tracking filter for obtaining slow-speed RPMs and phase
information, digital derivation of phase relative to input and
trigger channels using on-board timers, a peak-detector for
auto-scaling that is routed into a separate analog-to-digital
converter for peak detection, routing of a trigger channel that is
either raw or buffered into other analog channels, the use of
higher input oversampling for delta-sigma A/D for lower sampling
rate outputs to minimize anti-aliasing (AA) filter requirements,
the use of a CPLD as a clock-divider for a delta-sigma
analog-to-digital converter to achieve lower sampling rates without
the need for digital resampling, long blocks of data at a
high-sampling rate as opposed to multiple sets of data taken at
different sampling rates, storage of calibration data with a
maintenance history on-board card set, a rapid route creation
capability using hierarchical templates, intelligent management of
data collection bands, a neural net expert system using intelligent
management of data collection bands, use of a database hierarchy in
sensor data analysis, an expert system GUI graphical approach to
defining intelligent data collection bands and diagnoses for the
expert system, a graphical approach for back-calculation
definition, proposed bearing analysis methods, torsional vibration
detection/analysis utilizing transitory signal analysis, improved
integration using both analog and digital methods, adaptive
scheduling techniques for continuous monitoring of analog data in a
local environment, data acquisition parking features, a
self-sufficient data acquisition box, SD card storage, extended
onboard statistical capabilities for continuous monitoring, the use
of ambient, local, and vibration noise for prediction, smart route
changes based on incoming data or alarms to enable simultaneous
dynamic data for analysis or correlation, smart ODS and transfer
functions, a hierarchical multiplexer, identification of sensor
overload, RF identification and an inclinometer, continuous
ultrasonic monitoring, cloud-based, machine pattern recognition
based on fusion of remote, analog industrial sensors, cloud-based,
machine pattern analysis of state information from multiple analog
industrial sensors to provide anticipated state information for an
industrial system, cloud-based policy automation engine for IoT,
with creation, deployment, and management of IoT devices, on-device
sensor fusion and data storage for industrial IoT devices, a
self-organizing data marketplace for industrial IoT data,
self-organization of data pools based on utilization and/or yield
metrics, training AI models based on industry-specific feedback, a
self-organized swarm of industrial data collectors, an IoT
distributed ledger, a self-organizing collector, a
network-sensitive collector, a remotely organized collector, a
self-organizing storage for a multi-sensor data collector, a
self-organizing network coding for multi-sensor data network, a
wearable haptic user interface for an industrial sensor data
collector, with vibration, heat, electrical, and/or sound outputs,
heat maps displaying collected data for AR/VR, or automatically
tuned AR/VR visualization of data collected by a data
collector.
[0400] In embodiments, a platform is provided having one or more of
cloud-based, machine pattern recognition based on fusion of remote,
analog industrial sensors, cloud-based, machine pattern analysis of
state information from multiple analog industrial sensors to
provide anticipated state information for an industrial system, a
cloud-based policy automation engine for IoT, with creation,
deployment, and management of IoT devices, on-device sensor fusion
and data storage for industrial IoT devices, a self-organizing data
marketplace for industrial IoT data, self-organization of data
pools based on utilization and/or yield metrics, training AI models
based on industry-specific feedback, a self-organized swarm of
industrial data collectors, an IoT distributed ledger, a
self-organizing collector, a network-sensitive collector, a
remotely organized collector, a self-organizing storage for a
multi-sensor data collector, a self-organizing network coding for
multi-sensor data network, a wearable haptic user interface for an
industrial sensor data collector, with vibration, heat, electrical,
and/or sound outputs, heat maps displaying collected data for
AR/VR, or automatically tuned AR/VR visualization of data collected
by a data collector.
[0401] With regard to FIG. 18, a range of existing data sensing and
processing systems with industrial sensing, processing, and storage
systems 4500 include a streaming data collector 4510 that may be
configured to accept data in a range of formats as described
herein. In embodiments, the range of formats can include a data
format A 4520, a data format B 4522, a data format C 4524, and a
data format D 4528 that may be sourced from a range of sensors.
Moreover, the range of sensors can include an instrument A 4540, an
instrument B 4542, an instrument C 4544, and an instrument D 4548.
The streaming data collector 4510 may be configured with processing
capabilities that enable access to the individual formats while
leveraging the streaming, routing, self-organizing storage, and
other capabilities described herein.
[0402] FIG. 19 depicts methods and systems 4600 for industrial
machine sensor data streaming collection, processing, and storage
that facilitate use of a streaming data collector 4610 to collect
and obtain data from legacy instruments 4620 and streaming
instruments 4622. Legacy instruments 4620 and their data
methodologies may capture and provide data that is limited in
scope, due to the legacy systems and acquisition procedures, such
as existing data methodologies described above herein, to a
particular range of frequencies and the like. The streaming data
collector 4610 may be configured to capture streaming instrument
data 4632 as well as legacy instrument data 4630. The streaming
data collector 4610 may also be configured to capture current
streaming instruments 4620 and legacy instruments 4622 and sensors
using current and legacy data methodologies. These embodiments may
be useful in transition applications from the legacy instruments
and processing to the streaming instruments and processing that may
be current or desired instruments or methodologies. In embodiments,
the streaming data collector 4610 may be configured to process the
legacy instrument data 4630 so that it can be stored compatibly
with the streamed instrument data 4632. The streaming data
collector 4610 may process or parse the streamed instrument data
4632 based on the legacy instrument data 4630 to produce at least
one extraction of the streamed data 4642 that is compatible with
the legacy instrument data 4630 that can be processed into
translated legacy data 4640. In embodiments, extracted data 4650
that can include extracted portions of translated legacy data 4652
and streamed data 4654 may be stored in a format that facilitates
access and processing by legacy instrument data processing and
further processing that can emulate legacy instrument data
processing methods, and the like. In embodiments, the portions of
the translated legacy data 4652 may also be stored in a format that
facilitates processing with different methods that can take
advantage of the greater frequencies, resolution, and volume of
data possible with a streaming instrument.
[0403] FIG. 20 depicts alternate embodiments descriptive of methods
and systems 4700 for industrial machine sensor data streaming,
collection, processing, and storage that facilitate integration of
legacy instruments and processing. In embodiments, a streaming data
collector 4710 may be connected with an industrial machine 4712 and
may include a plurality of sensors, such as streaming sensors 4720
and 4722 that may be configured to sense aspects of the industrial
machine 4712 associated with at least one moving part of the
machine 4712. The sensors 4720 and 4722 (or more) may communicate
with one or more streaming devices 4740 that may facilitate
streaming data from one or more of the sensors to the streaming
data collector 4710. In embodiments, the industrial machine 4712
may also interface with or include one or more legacy instruments
4730 that may capture data associated with one or more moving parts
of the industrial machine 4712 and store that data into a legacy
data storage facility 4732.
[0404] In embodiments, a frequency and/or resolution detection
facility 4742 may be configured to facilitate detecting information
about legacy instrument sourced data, such as a frequency range of
the data or a resolution of the data, and the like. The detection
facility 4742 may operate on data directly from the legacy
instruments 4730 or from data stored in a legacy storage facility
4732. The detection facility 4742 may communicate information
detected about the legacy instruments 4730, its sourced data, and
its stored data 4732, or the like to the streaming data collector
4710. Alternatively, the detection facility 4742 may access
information, such as information about frequency ranges,
resolution, and the like that characterizes the sourced data from
the legacy instrument 4730 and/or may be accessed from a portion of
the legacy storage facility 4732.
[0405] In embodiments, the streaming data collector 4710 may be
configured with one or more automatic processors, algorithms,
and/or other data methodologies to match up information captured by
the one or more legacy instruments 4730 with a portion of data
being provided by the one or more streaming devices 4740 from the
one or more industrial machines 4712. Data from streaming devices
4740 may include a wider range of frequencies and resolutions than
the sourced data of legacy instruments 4730 and, therefore,
filtering and other such functions can be implemented to extract
data from the streaming devices 4740 that corresponds to the
sourced data of the legacy instruments 4730 in aspects such as
frequency range, resolution, and the like. In embodiments, the
configured streaming data collector 4710 may produce a plurality of
streams of data, including a stream of data that may correspond to
the stream of data from the streaming device 4740 and a separate
stream of data that is compatible, in some aspects, with the legacy
instrument sourced data and the infrastructure to ingest and
automatically process it. Alternatively, the streaming data
collector 4710 may output data in modes other than as a stream,
such as batches, aggregations, summaries, and the like.
[0406] Configured streaming data collector 4710 may communicate
with a stream storage facility 4764 for storing at least one of the
data outputs from the streaming device 4710 and data extracted
therefrom that may be compatible, in some aspects, with the sourced
data of the legacy instruments 4730. A legacy compatible output of
the configured streaming data collector 4710 may also be provided
to a format adaptor facility 4748, 4760 that may configure, adapt,
reformat, and make other adjustments to the legacy compatible data
so that it can be stored in a legacy compatible storage facility
4762 so that legacy processing facilities 4744 may execute data
processing methods on data in the legacy compatible storage
facility 4762 and the like that are configured to process the
sourced data of the legacy instruments 4730. In embodiments in
which legacy compatible data is stored in the stream storage
facility 4764, legacy processing facility 4744 may also
automatically process this data after optionally being processed by
format adaptor 4760. By arranging the data collection, streaming,
processing, formatting, and storage elements to provide data in a
format that is fully compatible with legacy instrument sourced
data, transition from a legacy system can be simplified, and the
sourced data from legacy instruments can be easily compared to
newly acquired data (with more content) without losing the legacy
value of the sourced data from the legacy instruments 4730.
[0407] FIG. 21 depicts alternate embodiments of the methods and
systems 4800 described herein for industrial machine sensor data
streaming, collection, processing, and storage that may be
compatible with legacy instrument data collection and processing.
In embodiments, processing industrial machine sensed data may be
accomplished in a variety of ways including aligning legacy and
streaming sources of data, such as by aligning stored legacy and
streaming data; aligning stored legacy data with a stream of sensed
data; and aligning legacy and streamed data as it is being
collected. In embodiments, an industrial machine 4810 may include,
communicate with, or be integrated with one or more stream data
sensors 4820 that may sense aspects of the industrial machine 4810
such as aspects of one or more moving parts of the machine. The
industrial machine 4810 may also communicate with, include, or be
integrated with one or more legacy data sensors 4830 that may sense
similar aspects of the industrial machine 4810. In embodiments, the
one or more legacy data sensors 4830 may provide sensed data to one
or more legacy data collectors 4840. The stream data sensors 4820
may produce an output that encompasses all aspects of (i.e., a
richer signal) and is compatible with sensed data from the legacy
data sensors 4830. The stream data sensors 4820 may provide
compatible data to the legacy data collector 4840. By mimicking the
legacy data sensors 4830 or their data streams, the stream data
sensors 4820 may replace (or serve as suitable duplicate for) one
or more legacy data sensors, such as during an upgrade of the
sensing and processing system of an industrial machine. Frequency
range, resolution, and the like may be mimicked by the stream data
so as to ensure that all forms of legacy data are captured or can
be derived from the stream data. In embodiments, format conversion,
if needed, can also be performed by the stream data sensors 4820.
The stream data sensors 4820 may also produce an alternate data
stream that is suitable for collection by the stream data collector
4850. In embodiments, such an alternate data stream may be a
superset of the legacy data sensor data in at least one or more of:
frequency range, resolution, duration of sensing the data, and the
like.
[0408] In embodiments, an industrial machine sensed data processing
facility 4860 may execute a wide range of sensed data processing
methods, some of which may be compatible with the data from legacy
data sensors 4830 and may produce outputs that may meet legacy
sensed data processing requirements. To facilitate use of a wide
range of data processing capabilities of processing facility 4860,
legacy and stream data may need to be aligned so that a compatible
portion of stream data may be extracted for processing with legacy
compatible methods and the like. In embodiments, FIG. 21 depicts
three different techniques for aligning stream data to legacy data.
A first alignment methodology 4862 includes aligning legacy data
output by the legacy data collector 4840 with stream data output by
the stream data collector 4850. As data is provided by the legacy
data collector 4840, aspects of the data may be detected, such as
resolution, frequency, duration, and the like, and may be used as
control for a processing method that identifies portions of a
stream of data from the stream data collector 4850 that are
purposely compatible with the legacy data. The processing facility
4860 may apply one or more legacy compatible methods on the
identified portions of the stream data to extract data that can be
easily compared to or referenced against the legacy data.
[0409] In embodiments, a second alignment methodology 4864 may
involve aligning streaming data with data from a legacy storage
facility 4882. In embodiments, a third alignment methodology 4868
may involve aligning stored stream data from a stream storage
facility 4884 with legacy data from the legacy data storage
facility 4882. In each of the methodologies 4862, 4864, 4868,
alignment data may be determined by processing the legacy data to
detect aspects such as resolution, duration, frequency range, and
the like. Alternatively, alignment may be performed by an alignment
facility, such as facilities using methodologies 4862, 4864, 4868
that may receive or may be configured with legacy data descriptive
information such as legacy frequency range, duration, resolution,
and the like.
[0410] In embodiments, an industrial machine sensing data
processing facility 4860 may have access to legacy compatible
methods and algorithms that may be stored in a legacy data
methodology storage facility 4880. These methodologies, algorithms,
or other data in the legacy algorithm storage facility 4880 may
also be a source of alignment information that could be
communicated by the industrial machine sensed data processing
facility 4860 to the various alignment facilities having
methodologies 4862, 4864, 4868. By having access to legacy
compatible algorithms and methodologies, the data processing
facility 4860 may facilitate processing legacy data, streamed data
that is compatible with legacy data, or portions of streamed data
that represent the legacy data to produce legacy compatible
analytics.
[0411] In embodiments, the data processing facility 4860 may
execute a wide range of other sensed data processing methods, such
as wavelet derivations and the like, to produce streamed data
analytics 4892. In embodiments, the streaming data collector 102,
4510, 4610, 4710 (FIGS. 3, 6, 18, 19, 20) or data processing
facility 4860 may include portable algorithms, methodologies, and
inputs that may be defined and extracted from data streams. In many
examples, a user or enterprise may already have existing and
effective methods related to analyzing specific pieces of machinery
and assets. These existing methods could be imported into the
configured streaming data collector 102, 4510, 4610, 4710 or the
data processing facility 4860 as portable algorithms or
methodologies. Data processing, such as described herein for the
configured streaming data collector 102, 4510, 4610, 4710 may also
match an algorithm or methodology to a situation, then extract data
from a stream to match to the data methodology from the legacy
acquisition or legacy acquisition techniques. In embodiments, the
streaming data collector 102, 4510, 4610, 4710 may be compatible
with many types of systems and may be compatible with systems
having varying degrees of criticality.
[0412] Exemplary industrial machine deployments of the methods and
systems described herein are now described. An industrial machine
may be a gas compressor. In an example, a gas compressor may
operate an oil pump on a very large turbo machine, such as a very
large turbo machine that includes 10,000 HP motors. The oil pump
may be a highly critical system as its failure could cause an
entire plant to shut down. The gas compressor in this example may
run four stages at a very high frequency, such as 36,000 RPM, and
may include tilt pad bearings that ride on an oil film. The oil
pump in this example may have roller bearings, such that if an
anticipated failure is not being picked up by a user, the oil pump
may stop running, and the entire turbo machine would fail.
Continuing with this example, the streaming data collector 102,
4510, 4610, 4710 may collect data related to vibrations, such as
casing vibration and proximity probe vibration. Other bearings
industrial machine examples may include generators, power plants,
boiler feed pumps, fans, forced draft fans, induced draft fans, and
the like. The streaming data collector 102, 4510, 4610, 4710 for a
bearings system used in the industrial gas industry may support
predictive analysis on the motors, such as that performed by
model-based expert systems--for example, using voltage, current,
and vibration as analysis metrics.
[0413] Another exemplary industrial machine deployment may be a
motor and the streaming data collector 102, 4510, 4610, 4710 that
may assist in the analysis of a motor by collecting voltage and
current data on the motor, for example.
[0414] Yet another exemplary industrial machine deployment may
include oil quality sensing. An industrial machine may conduct oil
analysis, and the streaming data collector 102, 4510, 4610, 4710
may assist in searching for fragments of metal in oil, for
example.
[0415] The methods and systems described herein may also be used in
combination with model-based systems. Model-based systems may
integrate with proximity probes. Proximity probes may be used to
sense problems with machinery and shut machinery down due to sensed
problems. A model-based system integrated with proximity probes may
measure a peak waveform and send a signal that shuts down machinery
based on the peak waveform measurement.
[0416] Enterprises that operate industrial machines may operate in
many diverse industries. These industries may include industries
that operate manufacturing lines, provide computing infrastructure,
support financial services, provide HVAC equipment, and the like.
These industries may be highly sensitive to lost operating time and
the cost incurred due to lost operating time. HVAC equipment
enterprises in particular may be concerned with data related to
ultrasound, vibration, IR, and the like, and may get much more
information about machine performance related to these metrics
using the methods and systems of industrial machine sensed data
streaming collection than from legacy systems.
[0417] Methods and systems described herein for industrial machine
sensor data streaming, collection, processing, and storage may be
configured to operate and integrate with existing data collection,
processing and storage systems and may include a method for
capturing a plurality of streams of sensed data from sensors
deployed to monitor aspects of an industrial machine associated
with at least one moving part of the machine; at least one of the
streams containing a plurality of frequencies of data. The method
may include identifying a subset of data in at least one of the
multiple streams that corresponds to data representing at least one
predefined frequency. The at least one predefined frequency is
represented by a set of data collected from alternate sensors
deployed to monitor aspects of the industrial machine associated
with the at least one moving part of the machine. The method may
further include processing the identified data with a data
processing facility that processes the identified data with data
methodologies configured to be applied to the set of data collected
from alternate sensors. Lastly, the method may include storing the
at least one of the streams of data, the identified subset of data,
and a result of processing the identified data in an electronic
data set.
[0418] The methods and systems may include a method for applying
data captured from sensors deployed to monitor aspects of an
industrial machine associated with at least one moving part of the
machine, the data captured with predefined lines of resolution
covering a predefined frequency range, to a frequency matching
facility that identifies a subset of data streamed from other
sensors deployed to monitor aspects of the industrial machine
associated with at least one moving part of the machine, the
streamed data comprising a plurality of lines of resolution and
frequency ranges, the subset of data identified corresponding to
the lines of resolution and predefined frequency range. This method
may include storing the subset of data in an electronic data record
in a format that corresponds to a format of the data captured with
predefined lines of resolution, and signaling to a data processing
facility the presence of the stored subset of data. This method may
optionally include processing the subset of data with at least one
of algorithms, methodologies, models, and pattern recognizers that
corresponds to algorithms, methodologies, models, and pattern
recognizers associated with processing the data captured with
predefined lines of resolution covering a predefined frequency
range.
[0419] The methods and systems may include a method for identifying
a subset of streamed sensor data. The sensor data is captured from
sensors deployed to monitor aspects of an industrial machine
associated with at least one moving part of the machine. The subset
of streamed sensor data is at predefined lines of resolution for a
predefined frequency range. The method includes establishing a
first logical route for communicating electronically between a
first computing facility performing the identifying and a second
computing facility. The identified subset of the streamed sensor
data is communicated exclusively over the established first logical
route when communicating the subset of streamed sensor data from
the first facility to the second facility. This method may further
include establishing a second logical route for communicating
electronically between the first computing facility and the second
computing facility for at least one portion of the streamed sensor
data that is not the identified subset. This method may further
include establishing a third logical route for communicating
electronically between the first computing facility and the second
computing facility for at least one portion of the streamed sensor
data that includes the identified subset and at least one other
portion of the data not represented by the identified subset.
[0420] The methods and systems may include a first data sensing and
processing system that captures first data from a first set of
sensors deployed to monitor aspects of an industrial machine
associated with at least one moving part of the machine, the first
data covering a set of lines of resolution and a frequency range.
This system may include a second data sensing and processing system
that captures and streams a second set of data from a second set of
sensors deployed to monitor aspects of the industrial machine
associated with at least one moving part of the machine, the second
data covering a plurality of lines of resolution that includes the
set of lines of resolution and a plurality of frequencies that
includes the frequency range. The system may enable: (1) selecting
a portion of the second data that corresponds to the set of lines
of resolution and the frequency range of the first data; and (2)
processing the selected portion of the second data with the first
data sensing and processing system.
[0421] The methods and systems may include a method for
automatically processing a portion of a stream of sensed data. The
sensed data received from a first set of sensors deployed to
monitor aspects of an industrial machine associated with at least
one moving part of the machine in response to an electronic data
structure that facilitates extracting a subset of the stream of
sensed data that corresponds to a set of sensed data received from
a second set of sensors deployed to monitor the aspects of the
industrial machine associated with the at least one moving part of
the machine. The set of sensed data is constrained to a frequency
range. The stream of sensed data includes a range of frequencies
that exceeds the frequency range of the set of sensed data. The
processing comprises executing data methodologies on a portion of
the stream of sensed data that is constrained to the frequency
range of the set of sensed data. The data methodologies are
configured to process the set of sensed data.
[0422] The methods and systems may include a method for receiving
first data from sensors deployed to monitor aspects of an
industrial machine associated with at least one moving part of the
machine. This method may further include: (1) detecting at least
one of a frequency range and lines of resolution represented by the
first data, and (2) receiving a stream of data from sensors
deployed to monitor the aspects of the industrial machine
associated with the at least one moving part of the machine. The
stream of data includes: a plurality of frequency ranges and a
plurality of lines of resolution that exceeds the frequency range
and the lines of resolution represented by the first data;
extracting a set of data from the stream of data that corresponds
to at least one of the frequency range and the lines of resolution
represented by the first data; and processing the extracted set of
data with a data processing method that is configured to process
data within the frequency range and within the lines of resolution
of the first data.
[0423] The methods and systems disclosed herein may include,
connect to, or be integrated with a data acquisition instrument and
in the many embodiments, FIG. 22 shows methods and systems 5000
that includes a data acquisition (DAQ) streaming instrument 5002
also known as an SDAQ. In embodiments, output from sensors 5010,
5012, 5014 may be of various types including vibration,
temperature, pressure, ultrasound and so on. In my many examples,
one of the sensors may be used. In further examples, many of the
sensors may be used and their signals may be used individually or
in predetermined combinations and/or at predetermined intervals,
circumstances, setups, and the like.
[0424] In embodiments, the output signals from the sensors 5010,
5012, 5014 may be fed into instrument inputs 5020, 5022, 5024 of
the DAQ instrument 5002 and may be configured with additional
streaming capabilities 5028. By way of these many examples, the
output signals from the sensors 5010, 5012, 5014, or more as
applicable, may be conditioned as an analog signal before
digitization with respect to at least scaling and filtering. The
signals may then be digitized by an analog-to-digital converter
5030. The signals received from all relevant channels (i.e., one or
more channels are switched on manually, by alarm, by route, and the
like) may be simultaneously sampled at a predetermined rate
sufficient to perform the maximum desired frequency analysis that
may be adjusted and readjusted as needed or otherwise held constant
to ensure compatibility or conformance with other relevant
datasets. In embodiments, the signals are sampled for a relatively
long time and gap-free as one continuous stream so as to enable
further post-processing at lower sampling rates with sufficient
individual sampling.
[0425] In embodiments, data may be streamed from a collection of
points and then the next set of data may be collected from
additional points according to a prescribed sequence, route, path,
or the like. In many examples, the sensors 5010, 5012, 5014 or more
may be moved to the next location according to the prescribed
sequence, route, pre-arranged configurations, or the like. In
certain examples, not all of the sensor 5010, 5012, 5014 may move
and therefore some may remain fixed in place and used for detection
of reference phase or the like.
[0426] In embodiments, a multiplex (mux) 5032 may be used to switch
to the next collection of points, to a mixture of the two methods
or collection patterns that may be combined, other predetermined
routes, and the like. The multiplexer 5032 may be stackable so as
to be laddered and effectively accept more channels than the DAQ
instrument 5002 provides. In examples, the DAQ instrument 5002 may
provide eight channels while the multiplexer 5032 may be stacked to
supply 32 channels. Further variations are possible with one more
multiplexers. In embodiments, the multiplexer 5032 may be fed into
the DAQ instrument 5002 through an instrument input 5034. In
embodiments, the DAQ instrument 5002 may include a controller 5038
that may take the form of an onboard controller, a PC, other
connected devices, network based services, and combinations
thereof.
[0427] In embodiments, the sequence and panel conditions used to
govern the data collection process may be obtained from the
multimedia probe (MMP) and probe control, sequence and analytical
(PCSA) information store 5040. In embodiments, the information
store 5040 may be onboard the DAQ instrument 5002. In embodiments,
contents of the information store 5040 may be obtained through a
cloud network facility, from other DAQ instruments, from other
connected devices, from the machine being sensed, other relevant
sources, and combinations thereof. In embodiments, the information
store 5040 may include such items as the hierarchical structural
relationships of the machine, e.g., a machine contains
predetermined pieces of equipment, each of which may contain one or
more shafts and each of those shafts may have multiple associated
bearings. Each of those types of bearings may be monitored by
specific types of transducers or probes, according to one or more
specific prescribed sequences (paths, routes, and the like) and
with one or more specific panel conditions that may be set on the
one or more DAQ instruments 5002. By way of this example, the panel
conditions may include hardware specific switch settings or other
collection parameters. In many examples, collection parameters
include but are not limited to a sampling rate, AC/DC coupling,
voltage range and gain, integration, high and low pass filtering,
anti-aliasing filtering, ICP.TM. transducers and other
integrated-circuit piezoelectric transducers, 4-20 mA loop sensors,
and the like. In embodiments, the information store 5040 may also
include machinery specific features that may be important for
proper analysis such as gear teeth for a gear, number blades in a
pump impeller, number of motor rotor bars, bearing specific
parameters necessary for calculating bearing frequencies,
revolution per minutes information of all rotating elements and
multiples of those RPM ranges, and the like. Information in the
information store may also be used to extract stream data 5050 for
permanent storage.
[0428] Based on directions from the DAQ API software 5052,
digitized waveforms may be uploaded using DAQ driver services 5054
of a driver onboard the DAQ instrument 5002. In embodiments, data
may then be fed into a raw data server 5058 which may store the
stream data 5050 in a stream data repository 5060. In embodiments,
this data storage area is typically meant for storage until the
data is copied off of the DAQ instrument 5002 and verified. The DAQ
API 5052 may also direct the local data control application 5062 to
extract and process the recently obtained stream data 5050 and
convert it to the same or lower sampling rates of sufficient length
to effect one or more desired resolutions. By way of these
examples, this data may be converted to spectra, averaged, and
processed in a variety of ways and stored, at least temporarily, as
extracted/processed (EP) data 5064. It will be appreciated in light
of the disclosure that legacy data may require its own sampling
rates and resolution to ensure compatibility and often this
sampling rate may not be integer proportional to the acquired
sampling rate. It will also be appreciated in light of the
disclosure that this may be especially relevant for order-sampled
data whose sampling frequency is related directly to an external
frequency (typically the running speed of the machine or its local
componentry) rather than the more-standard sampling rates employed
by the internal crystals, clock functions, or the like of the DAQ
instrument (e.g., values of Fmax of 100, 200, 500, 1K, 2K, 5K, 10K,
20K, and so on).
[0429] In embodiments, the extract/process (EP) align module 5068
of the local data control application 5062 may be able to
fractionally adjust the sampling rates to these non-integer ratio
rates satisfying an important requirement for making data
compatible with legacy systems. In embodiments, fractional rates
may also be converted to integer ratio rates more readily because
the length of the data to be processed may be adjustable. It will
be appreciated in light of the disclosure that if the data was not
streamed and just stored as spectra with the standard or
predetermined Fmax, it may be impossible in certain situations to
convert it retroactively and accurately to the order-sampled data.
It will also be appreciated in light of the disclosure that
internal identification issues may also need to be reconciled. In
many examples, stream data may be converted to the proper sampling
rate and resolution as described and stored (albeit temporarily) in
an EP legacy data repository 5070 to ensure compatibility with
legacy data.
[0430] To support legacy data identification issues, a user input
module 5072 is shown in many embodiments should there be no
automated process (whether partially or wholly) for identification
translation. In such examples, one or more legacy systems (i.e.,
pre-existing data acquisition) may be characterized in that the
data to be imported is in a fully standardized format such as a
Mimosa.TM. format, and other similar formats. Moreover, sufficient
indentation of the legacy data and/or the one or more machines from
which the legacy data was produced may be required in the
completion of an identification mapping table 5074 to associate and
link a portion of the legacy data to a portion of the newly
acquired streamed data 5050. In many examples, the end user and/or
legacy vendor may be able to supply sufficient information to
complete at least a portion of a functioning identification (ID)
mapping table 5074 and therefore may provide the necessary database
schema for the raw data of the legacy system to be used for
comparison, analysis, and manipulation of newly streamed data
5050.
[0431] In embodiments, the local data control application 5062 may
also direct streaming data as well as extracted/processed (EP) data
to a cloud network facility 5080 via wired or wireless
transmission. From the cloud network facility 5080 other devices
may access, receive, and maintain data including the data from a
master raw data server (MRDS) 5082. The movement, distribution,
storage, and retrieval of data remote to the DAQ instrument 5002
may be coordinated by the cloud data management services ("CDMS")
5084.
[0432] FIG. 23 shows additional methods and systems that include
the DAQ instrument 5002 accessing related cloud based services. In
embodiments, the DAQ API 5052 may control the data collection
process as well as its sequence. By way of these examples, the DAQ
API 5052 may provide the capability for editing processes, viewing
plots of the data, controlling the processing of that data, viewing
the output data in all its myriad forms, analyzing this data
including expert analysis, and communicating with external devices
via the local data control application 5062 and with the CDMS 5084
via the cloud network facility 5080. In embodiments, the DAQ API
5052 may also govern the movement of data, its filtering, as well
as many other housekeeping functions.
[0433] In embodiments, an expert analysis module 5100 may generate
reports 5102 that may use machine or measurement point specific
information from the information store 5040 to analyze the stream
data 5050 using a stream data analyzer module 5104 and the local
data control application 5062 with the extract/process ("EP") align
module 5068. In embodiments, the expert analysis module 5100 may
generate new alarms or ingest alarm settings into an alarms module
5108 that is relevant to the stream data 5050. In embodiments, the
stream data analyzer module 5104 may provide a manual or automated
mechanism for extracting meaningful information from the stream
data 5050 in a variety of plotting and report formats. In
embodiments, a supervisory control of the expert analysis module
5100 is provided by the DAQ API 5052. In further examples, the
expert analysis module 5100 may be supplied (wholly or partially)
via the cloud network facility 5080. In many examples, the expert
analysis module 5100 via the cloud may be used rather than a
locally-deployed expert analysis module 5100 for various reasons
such as using the most up-to-date software version, more processing
capability, a bigger volume of historical data to reference, and so
on. In many examples, it may be important that the expert analysis
module 5100 be available when an internet connection cannot be
established so having this redundancy may be crucial for seamless
and time efficient operation. Toward that end, many of the modular
software applications and databases available to the DAQ instrument
5002 where applicable may be implemented with system component
redundancy to provide operational robustness to provide
connectivity to cloud services when needed but also operate
successfully in isolated scenarios where connectivity is not
available and sometime not available purposefully to increase
security and the like.
[0434] In embodiments, the DAQ instrument acquisition may require a
real time operating system ("RTOS") for the hardware especially for
streamed gap-free data that is acquired by a PC. In some instances,
the requirement for a RTOS may result in (or may require) expensive
custom hardware and software capable of running such a system. In
many embodiments, such expensive custom hardware and software may
be avoided and an RTOS may be effectively and sufficiently
implemented using a standard Windows.TM. operating systems or
similar environments including the system interrupts in the
procedural flow of a dedicated application included in such
operating systems.
[0435] The methods and systems disclosed herein may include,
connect to, or be integrated with one or more DAQ instruments and
in the many embodiments, FIG. 24 shows methods and systems 5150
that include the DAQ instrument 5002 (also known as a streaming DAQ
or an SDAQ). In embodiments, the DAQ instrument 5002 may
effectively and sufficiently implement an RTOS using standard
windows operating system (or other similar personal computing
systems) that may include a software driver configured with a First
In, First Out (FIFO) memory area 5152. The FIFO memory area 5152
may be maintained and hold information for a sufficient amount of
time to handle a worst-case interrupt that it may face from the
local operating system to effectively provide the RTOS. In many
examples, configurations on a local personal computer or connected
device may be maintained to minimize operating system interrupts.
To support this, the configurations may be maintained, controlled,
or adjusted to eliminate (or be isolated from) any exposure to
extreme environments where operating system interrupts may become
an issue. In embodiments, the DAQ instrument 5002 may produce a
notification, alarm, message, or the like to notify a user when any
gap errors are detected. In these many examples, such errors may be
shown to be rare and even if they occur, the data may be adjusted
knowing when they occurred should such a situation arise.
[0436] In embodiments, the DAQ instrument 5002 may maintain a
sufficiently large FIFO memory area 5152 that may buffer the
incoming data so as to be not affected by operating system
interrupts when acquiring data. It will be appreciated in light of
the disclosure that the predetermined size of the FIFO memory area
5152 may be based on operating system interrupts that may include
Windows system and application functions such as the writing of
data to Disk or SSD, plotting, GUI interactions and standard
Windows tasks, low-level driver tasks such as servicing the DAQ
hardware and retrieving the data in bursts, and the like.
[0437] In embodiments, the computer, controller, connected device
or the like that may be included in the DAQ instrument 5002 may be
configured to acquire data from the one or more hardware devices
over a USB port, firewire, ethernet, or the like. In embodiments,
the DAQ driver services 5054 may be configured to have data
delivered to it periodically so as to facilitate providing a
channel specific FIFO memory buffer that may be configured to not
miss data, i.e., it is gap-free. In embodiments, the DAQ driver
services 5054 may be configured so as to maintain an even larger
(than the device) channel specific FIFO area 5152 that it fills
with new data obtained from the device. In embodiments, the DAQ
driver services 5054 may be configured to employ a further process
in that the raw data server 5058 may take data from the FIFO 5110
and may write it as a contiguous stream to non-volatile storage
areas such as the stream data repository 5060 that may be
configured as one or more disk drives, SSDs, or the like. In
embodiments, the FIFO 5110 may be configured to include a starting
and stopping marker or pointer to mark where the latest most
current stream was written. By way of these examples, a FIFO end
marker 5114 may be configured to mark the end of the most current
data until it reaches the end of the spooler and then wraps around
constantly cycling around. In these examples, there is always one
megabyte (or other configured capacities) of the most current data
available in the FIFO 5110 once the spooler fills up. It will be
appreciated in light of the disclosure that further configurations
of the FIFO memory area may be employed. In embodiments, the DAQ
driver services 5054 may be configured to use the DAQ API 5052 to
pipe the most recent data to a high-level application for
processing, graphing and analysis purposes. In some examples, it is
not required that this data be gap-free but even in these
instances, it is helpful to identify and mark the gaps in the data.
Moreover, these data updates may be configured to be frequent
enough so that the user would perceive the data as live. In the
many embodiments, the raw data is flushed to non-volatile storage
without a gap at least for the prescribed amount of time and
examples of the prescribed amount of time may be about thirty
seconds to over four hours. It will be appreciated in light of the
disclosure that many pieces of equipment and their components may
contribute to the relative needed duration of the stream of
gap-free data and those durations may be over four hours when
relatively low speeds are present in large numbers, when
non-periodic transient activity is occurring on a relatively long
time frame, when duty cycle only permits operation in relevant
ranges for restricted durations and the like.
[0438] With reference to FIG. 23, the stream data analyzer module
5104 may provide for the manual or extraction of information from
the data stream in a variety of plotting and report formats. In
embodiments, resampling, filtering (including anti-aliasing),
transfer functions, spectrum analysis, enveloping, averaging, peak
detection functionality, as well as a host of other signal
processing tools, may be available for the analyst to analyze the
stream data and to generate a very large array of snapshots. It
will be appreciated in light of the disclosure that much larger
arrays of snapshots are created than ever would have been possible
by scheduling the collection of snapshots beforehand, i.e., during
the initial data acquisition for the measurement point in
question.
[0439] FIG. 25 depicts a display 5200 whose viewable content 5202
may be accessed locally or remotely, wholly or partially. In many
embodiments, the display 5200 may be part of the DAQ instrument
5002, may be part of the PC or connected device 5038 that may be
part of the DAQ instrument 5002, or its viewable content 5202 may
be viewable from associated network connected displays. In further
examples, the viewable content 5202 of the display 5200 or portions
thereof may be ported to one or more relevant network addresses. In
the many embodiments, the viewable content 5202 may include a
screen 5204 that shows, for example, an approximately two-minute
data stream 5208 may be collected at a sampling rate of 25.6 kHz
for four channels 5220, 5222, 5224, 5228, simultaneously. By way of
these examples and in these configurations, the length of the data
may be approximately 3.1 megabytes. It will be appreciated in light
of the disclosure that the data stream (including each of its four
channels or as many as applicable) may be replayed in some aspects
like a magnetic tape recording (e.g. a reel-to-reel or a cassette)
with all of the controls normally associated with playback such as
forward 5230, fast forward, backward 5232, fast rewind, step back,
step forward, advance to time point, retreat to time point,
beginning 5234, end, 5238, play 5240, stop 5242, and the like.
Additionally, the playback of the data stream may further be
configured to set a width of the data stream to be shown as a
contiguous subset of the entire stream. In the example with a
two-minute data stream, the entire two minutes may be selected by
the "select all" button 5244, or some subset thereof may be
selected with the controls on the screen 5204 or that may be placed
on the screen 5204 by configuring the display 5200 and the DAQ
instrument 5002. In this example, the "process selected data"
button 5250 on the screen 5204 may be selected to commit to a
selection of the data stream.
[0440] FIG. 26 depicts the many embodiments that include a screen
5250 on the display 5200 that shows results of selecting all of the
data for this example. In embodiments, the screen 5250 in FIG. 26
may provide the same or similar playback capabilities as what is
depicted on the screen 5204 shown in FIG. 25 but also includes
resampling capabilities, waveform displays, and spectrum displays.
In light of the disclosure, it will be appreciated that this
functionality may permit the user to choose in many situations any
Fmax less than that supported by the original streaming sampling
rate. In embodiments, any section of any size may be selected and
further processing, analytics, and tools for viewing and dissecting
the data may be provided. In embodiments, the screen 5250 may
include four windows 5252, 5254, 5258, 5260 that show the stream
data from the four channels 5220, 5222, 5224, 5228 of FIG. 25. In
embodiments, the screen 5250 may also include offset and overlap
controls 5262, resampling controls 5264, and other similar
controls.
[0441] In many examples, any one of many transfer functions may be
established between any two channels, such as the two channels
5280, 5282 that may be shown on a screen 5284, shown on the display
5200, as depicted in FIG. 27. The selection of the two channels
5280, 5282 on the screen 5284 may permit the user to depict the
output of the transfer function on any of the screens including
screen 5284 and screen 5204.
[0442] In embodiments, FIG. 28 shows a high-resolution spectrum
screen 5300 on the display 5200 with a waveform view 5302, full
cursor control 5304 and a peak extraction view 5308. In these
examples, the peak extraction view 5308 may be configured with a
resolved configuration 5310 that may be configured to provide
enhanced amplitude and frequency accuracy and may use spectral
sideband energy distribution. The peak extraction view 5308 may
also be configured with averaging 5312, phase and cursor vector
information 5314, and the like.
[0443] In embodiments, FIG. 29 shows an enveloping screen 5350 on
the display 5200 with a waveform view 5352, and a spectral format
view 5354. The views 5352, 5354 on the enveloping screen 5350 may
display modulation from the signal in both waveform and spectral
formats. In embodiments, FIG. 30 shows a relative phase screen 5380
on the display 5200 with four phase views 5382, 5384, 5388, 5390.
The four phase views 5382, 5384, 5388, 5390 relate to the on
spectrum the enveloping screen 5350 that may display modulation
from the signal in waveform format in view 5352 and spectral format
in view 5354. In embodiments, the reference channel control 5392
may be selected to use channel four as a reference channel to
determine relative phase between each of the channels.
[0444] It will be appreciated in light of the disclosure that the
sampling rates of vibration data of up to 100 kHz (or higher in
some scenarios) may be utilized for non-vibration sensors as well.
In doing so, it will further be appreciated in light of the
disclosure that stream data in such durations at these sampling
rates may uncover new patterns to be analyzed due in no small part
that many of these types of sensors have not been utilized in this
manner. It will also be appreciated in light of the disclosure that
different sensors used in machinery condition monitoring may
provide measurements more akin to static levels rather than
fast-acting dynamic signals. In some cases, faster response time
transducers may have to be used prior to achieving the faster
sampling rates.
[0445] In many embodiments, sensors may have a relatively static
output such as temperature, pressure, or flow but may still be
analyzed with the dynamic signal processing system and
methodologies as disclosed herein. It will be appreciated in light
of the disclosure that the time scale, in many examples, may be
slowed down. In many examples, a collection of temperature readings
collected approximately every minute for over two weeks may be
analyzed for their variation solely or in collaboration or in
fusion with other relevant sensors. By way of these examples, the
direct current level or average level may be omitted from all the
readings (e.g., by subtraction) and the resulting delta
measurements may be processed (e.g., through a Fourier transform).
From these examples, resulting spectral lines may correlate to
specific machinery behavior or other symptoms present in industrial
system processes. In further examples, other techniques include
enveloping that may look for modulation, wavelets that may look for
spectral patterns that last only for a short time (e.g., bursts),
cross-channel analysis to look for correlations with other sensors
including vibration, and the like.
[0446] FIG. 31 shows a DAQ instrument 5400 that may be integrated
with one or more analog sensors 5402 and endpoint nodes 5404 to
provide a streaming sensor 5410 or smart sensors that may take in
analog signals and then process and digitize them, and then
transmit them to one or more external monitoring systems 5412 in
the many embodiments that may be connected to, interfacing with, or
integrated with the methods and systems disclosed herein. The
monitoring system 5412 may include a streaming hub server 5420 that
may communicate with the CDMS 5084. In embodiments, the CDMS 5084
may contact, use, and integrate with cloud data 5430 and cloud
services 5432 that may be accessible through one or more cloud
network facilities 5080. In embodiments, the streaming hub server
5420 may connect with another streaming sensor 5440 that may
include a DAQ instrument 5442, an endpoint node 5444, and the one
or more analog sensors such as analog sensor 5448. The steaming hub
server 5420 may connect with other streaming sensors such as the
streaming sensor 5460 that may include a DAQ instrument 5462, an
endpoint node 5464, and the one or more analog sensors such as
analog sensor 5468.
[0447] In embodiments, there may be additional streaming hub
servers such as the steaming hub server 5480 that may connect with
other streaming sensors such as the streaming sensor 5490 that may
include a DAQ instrument 5492, an endpoint node 5494, and the one
or more analog sensors such as analog sensor 5498. In embodiments,
the streaming hub server 5480 may also connect with other streaming
sensors such as the streaming sensor 5500 that may include a DAQ
instrument 5502, an endpoint node 5504, and the one or more analog
sensors such as analog sensor 5508. In embodiments, the
transmission may include averaged overall levels and in other
examples may include dynamic signal sampled at a prescribed and/or
fixed rate. In embodiments, the streaming sensors 5410, 5440, 5460,
5490, and 5500 may be configured to acquire analog signals and then
apply signal conditioning to those analog signals including
coupling, averaging, integrating, differentiating, scaling,
filtering of various kinds, and the like. The streaming sensors
5410, 5440, 5460, 5490, and 5500 may be configured to digitize the
analog signals at an acceptable rate and resolution (number of
bits) and to process further the digitized signal when required.
The streaming sensors 5410, 5440, 5460, 5490, and 5500 may be
configured to transmit the digitized signals at pre-determined,
adjustable, and re-adjustable rates. In embodiments, the streaming
sensors 5410, 5440, 5460, 5490, and 5500 are configured to acquire,
digitize, process, and transmit data at a sufficient effective rate
so that a relatively consistent stream of data may be maintained
for a suitable amount of time so that a large number of effective
analyses may be shown to be possible. In the many embodiments,
there would be no gaps in the data stream and the length of data
should be relatively long, ideally for an unlimited amount of time,
although practical considerations typically require ending the
stream. It will be appreciated in light of the disclosure that this
long duration data stream with effectively no gap in the stream is
in contrast to the more commonly used burst collection where data
is collected for a relatively short period of time (i.e., a short
burst of collection), followed by a pause, and then perhaps another
burst collection and so on. In the commonly used collections of
data collected over noncontiguous bursts, data would be collected
at a slow rate for low frequency analysis and high frequency for
high frequency analysis. In many embodiments of the present
disclosure, in contrast, the streaming data is being collected (i)
once, (ii) at the highest useful and possible sampling rate, and
(iii) for a long enough time that low frequency analysis may be
performed as well as high frequency. To facilitate the collection
of the streaming data, enough storage memory must be available on
the one or more streaming sensors such as the streaming sensors
5410, 5440, 5460, 5490, 5500 so that new data may be off-loaded
externally to another system before the memory overflows. In
embodiments, data in this memory would be stored into and accessed
from "First-In, First-Out" ("FIFO") mode. In these examples, the
memory with a FIFO area may be a dual port so that the sensor
controller may write to one part of it while the external system
reads from a different part. In embodiments, data flow traffic may
be managed by semaphore logic.
[0448] It will be appreciated in light of the disclosure that
vibration transducers that are larger in mass will have a lower
linear frequency response range because the natural resonance of
the probe is inversely related to the square root of the mass and
will be lowered. Toward that end, a resonant response is inherently
non-linear and so a transducer with a lower natural frequency will
have a narrower linear passband frequency response. It will also be
appreciated in light of the disclosure that above the natural
frequency the amplitude response of the sensor will taper off to
negligible levels rendering it even more unusable. With that in
mind, high frequency accelerometers, for this reason, tend to be
quite small in mass, to the order of half of a gram. It will also
be appreciated in light of the disclosure that adding the required
signal processing and digitizing electronics required for streaming
may, in certain situations, render the sensors incapable in many
instances of measuring high-frequency activity.
[0449] In embodiments, streaming hubs such as the streaming hubs
5420, 5480 may effectively move the electronics required for
streaming to an external hub via cable. It will be appreciated in
light of the disclosure that the streaming hubs may be located
virtually next to the streaming sensors or up to a distance
supported by the electronic driving capability of the hub. In
instances where an internet cache protocol ("ICP") is used, the
distance supported by the electronic driving capability of the hub
would be anywhere from 100 to 1000 feet (30.5 to 305 meters) based
on desired frequency response, cable capacitance, and the like. In
embodiments, the streaming hubs may be positioned in a location
convenient for receiving power as well as connecting to a network
(be it LAN or WAN). In embodiments, other power options would
include solar, thermal as well as energy harvesting. Transfer
between the streaming sensors and any external systems may be
wireless or wired and may include such standard communication
technologies as 802.11 and 900 MHz wireless systems, Ethernet, USB,
firewire and so on.
[0450] With reference to FIG. 22, the many examples of the DAQ
instrument 5002 include embodiments where data that may be uploaded
from the local data control application 5062 to the master raw data
server ("MRDS") 5082. In embodiments, information in the multimedia
probe ("MMP") and probe control, sequence and analytical ("PCSA")
information store 5040 may also be downloaded from the MRDS 5082
down to the DAQ instrument 5002. Further details of the MRDS 5082
are shown in FIG. 32 including embodiments where data may be
transferred to the MRDS 5082 from the DAQ instrument 5002 via a
wired or wireless network, or through connection to one or more
portable media, drive, other network connections, or the like. In
embodiments, the DAQ instrument 5002 may be configured to be
portable and may be carried on one or more predetermined routes to
assess predefined points of measurement. In these many examples,
the operating system that may be included in the MRDS 5082 may be
Windows.TM., Linux.TM. or MacOS.TM. operating systems, or other
similar operating systems. Further, in these arrangements, the
operating system, modules for the operating system, and other
needed libraries, data storage, and the like may be accessible
wholly or partially through access to the cloud network facility
5080. In embodiments, the MRDS 5082 may reside directly on the DAQ
instrument 5002, especially in on-line system examples. In
embodiments, the DAQ instrument 5002 may be linked on an
intra-network in a facility but may otherwise be behind a firewall.
In further examples, the DAQ instrument 5002 may be linked to the
cloud network facility 5080. In the various embodiments, one of the
computers or mobile computing devices may be effectively designated
the MRDS 5082 to which all of the other computing devices may feed
it data such as one of the MRDS 6104, as depicted in FIGS. 41 and
42. In the many examples where the DAQ instrument 5002 may be
deployed and configured to receive stream data in a swarm
environment, one or more of the DAQ instruments 5002 may be
effectively designated the MRDS 5082 to which all of the other
computing devices may feed it data. In the many examples where the
DAQ instrument 5002 may be deployed and configured to receive
stream data in an environment where the methods and systems
disclosed herein are intelligently assigning, controlling,
adjusting, and re-adjusting data pools, computing resources,
network bandwidth for local data collection, and the like, one or
more of the DAQ instruments 5002 may be effectively designated the
MRDS 5082 to which all of the other computing devices may feed it
data.
[0451] With further reference to FIG. 32, new raw streaming data,
data that have been through extract, process, and align processes
(EP data), and the like may be uploaded to one or more master raw
data servers as needed or as scaled in various environments. In
embodiments, a master raw data server ("MRDS") 5700 may connect to
and receive data from other master raw data servers such as the
MRDS 5082. The MRDS 5700 may include a data distribution manager
module 5702. In embodiments, the new raw streaming data may be
stored in the new stream data repository 5704. In many instances,
like raw data streams stored on the DAQ instrument 5002, the new
stream data repository 5704 and new extract and process data
repository 5708 may be similarly configured as a temporary storage
area.
[0452] In embodiments, the MRDS 5700 may include a stream data
analyzer module with an extract and process alignment module 5710.
The analyzer module 5710 may be shown to be a more robust data
analyzer and extractor than may be typically found on portable
streaming DAQ instruments although it may be deployed on the DAQ
instrument 5002 as well. In embodiments, the analyzer module 5710
takes streaming data and instantiates it at a specific sampling
rate and resolution similar to the local data control module 5062
on the DAQ instrument 5002. The specific sampling rate and
resolution of the analyzer module 5710 may be based on either user
input 5712 or automated extractions from a multimedia probe ("MMP")
and the probe control, sequence and analytical ("PCSA") information
store 5714 and/or an identification mapping table 5718, which may
require the user input 5712 if there is incomplete information
regarding various forms of legacy data similar to as was detailed
with the DAQ instrument 5002. In embodiments, legacy data may be
processed with the analyzer module 5710 and may be stored in one or
more temporary holding areas such as a new legacy data repository
5720. One or more temporary areas may be configured to hold data
until it is copied to an archive and verified. The analyzer 5710
module may also facilitate in-depth analysis by providing many
varying types of signal processing tools including but not limited
to filtering, Fourier transforms, weighting, resampling, envelope
demodulation, wavelets, two-channel analysis, and the like. From
this analysis, many different types of plots and mini-reports may
be generated from a reports and plots module 5724. In embodiments,
data is sent to the processing, analysis, reports, and archiving
("PARA") server 5730 upon user initiation or in an automated
fashion especially for on-line systems.
[0453] In embodiments, a PARA server 5750 may connect to and
receive data from other PARA servers such as the PARA server 5730.
With reference to FIG. 34, the PARA server 5730 may provide data to
a supervisory module 5752 on the PARA server 5750 that may be
configured to provide at least one of processing, analysis,
reporting, archiving, supervisory, and similar functionalities. The
supervisory module 5752 may also contain extract, process align
functionality and the like. In embodiments, incoming streaming data
may first be stored in a raw data stream archive 5760 after being
properly validated. Based on the analytical requirements derived
from a multimedia probe ("MMP") and probe control, sequence and
analytical ("PCSA") information store 5762 as well as user
settings, data may be extracted, analyzed, and stored in an extract
and process ("EP") raw data archive 5764. In embodiments, various
reports from a reports module 5768 are generated from the
supervisory module 5752. The various reports from the reports
module 5768 include trend plots of various smart bands, overalls
along with statistical patterns, and the like. In embodiments, the
reports module 5768 may also be configured to compare incoming data
to historical data. By way of these examples, the reports module
5768 may search for and analyze adverse trends, sudden changes,
machinery defect patterns, and the like. In embodiments, the PARA
server 5750 may include an expert analysis module 5770 from which
reports are generated and analysis may be conducted. Upon
completion, archived data may be fed to a local master server
("LMS") 5772 via a server module 5774 that may connect to the local
area network. In embodiments, archived data may also be fed to the
LMS 5772 via a cloud data management server ("CDMS") 5778 through a
server module for a cloud network facility 5080. In embodiments,
the supervisory module 5752 on the PARA server 5750 may be
configured to provide at least one of processing, analysis,
reporting, archiving, supervisory, and similar functionalities from
which alarms may be generated, rated, stored, modified, reassigned,
and the like with an alarm generator module 5782.
[0454] FIG. 34 depicts various embodiments that include a PARA
server 5800 and its connection to LAN 5802. In embodiments, one or
more DAQ instruments such as the DAQ instrument 5002 may receive
and process analog data from one or more analog sensors 5710 that
may be fed into the DAQ instrument 5002. As discussed herein, the
DAQ instrument 5002 may create a digital stream of data based on
the ingested analog data from the one or more analog sensors. The
digital stream from the DAQ instrument 5002 may be uploaded to the
MRDS 5082 and from there, it may be sent to the PARA server 5800
where multiple terminals, such as terminal 5810 5812, 5814, may
each interface with it or the MRDS 5082 and view the data and/or
analysis reports. In embodiments, the PARA server 5800 may
communicate with a network data server 5820 that may include a LMS
5822. In these examples, the LMS 5822 may be configured as an
optional storage area for archived data. The LMS 5822 may also be
configured as an external driver that may be connected to a PC or
other computing device that may run the LMS 5822; or the LMS 5822
may be directly run by the PARA server 5800 where the LMS 5822 may
be configured to operate and coexist with the PARA server 5800. The
LMS 5822 may connect with a raw data stream archive 5824, an
extract and process ("EP") raw data archive 5828, and a MMP and
probe control, sequence and analytical ("PCSA") information store
5830. In embodiments, a CDMS 5832 may also connect to the LAN 5802
and may also support the archiving of data.
[0455] In embodiments, portable connected devices 5850 such as a
tablet 5852 and a smart phone 5854 may connect the CDMS 5832 using
web APIs 5860 and 5862, respectively, as depicted in FIG. 35. The
APIs 5860, 5862 may be configured to execute in a browser and may
permit access via a cloud network facility 5870 of all (or some of)
the functions previously discussed as accessible through the PARA
Server 5800. In embodiments, computing devices of a user 5880 such
as computing devices 5882, 5884, 5888 may also access the cloud
network facility 5870 via a browser or other connection in order to
receive the same functionality. In embodiments, thin-client apps
which do not require any other device drivers and may be
facilitated by web services supported by cloud services 5890 and
cloud data 5892. In many examples, the thin-client apps may be
developed and reconfigured using, for example, the visual
high-level LabVIEW.TM. programming language with NXG.TM. Web-based
virtual interface subroutines. In embodiments, thin client apps may
provide high-level graphing functions such as those supported by
LabVIEW.TM. tools. In embodiments, the LabVIEW.TM. tools may
generate JSCRIPT.TM. code and JAVA.TM. code that may be edited
post-compilation. The NXG.TM. tools may generate Web VI's that may
not require any specialized driver and only some RESTful.TM.
services which may be readily installed from any browser. It will
be appreciated in light of the disclosure that because various
applications may be run inside a browser, the applications may be
run on any operating system, such as Windows.TM., Linux.TM., and
Android.TM. operating systems especially for personal devices,
mobile devices, portable connected devices, and the like.
[0456] In embodiments, the CDMS 5832 is depicted in greater detail
in FIG. 36. In embodiments, the CDMS 5832 may provide all of the
data storage and services that the PARA Server 5800 (FIG. 34) may
provide. In contrast, all of the API's may be web API's which may
run in a browser and all other apps may run on the PARA Server 5800
or the DAQ instrument 5002 which may typically be Windows.TM.,
Linux.TM. or other similar operating systems. In embodiments, the
CDMS 5832 includes at least one of or combinations of the following
functions: the CDMS 5832 may include a cloud GUI 5900 that may be
configured to provide access to all data plots including trend,
waveform, spectra, envelope, transfer function, logs of measurement
events, analysis including expert, utilities, and the like. In
embodiments, the CDMS 5832 may include a cloud data exchange 5902
configured to facilitate the transfer of data to and from the cloud
network facility 5870. In embodiments, the CDMS 5832 may include a
cloud plots/trends module 5904 that may be configured to show all
plots via web apps including trend, waveform, spectra, envelope,
transfer function, and the like. In embodiments, the CDMS 5832 may
include a cloud reporter 5908 that may be configured to provide all
analysis reports, logs, expert analysis, trend plots, statistical
information, and the like. In embodiments, the CDMS 5832 may
include a cloud alarm module 5910. Alarms from the cloud alarm
module 5910 may be generated and may be sent to various devices
5920 via email, texts, or other messaging mechanisms. From the
various modules, data may be stored in new data 5914. The various
devices 5920 may include a terminal 5922, portable connected device
5924, or a tablet 5928. The alarms from the cloud alarm module are
designed to be interactive so that the end user may acknowledge
alarms in order to avoid receiving redundant alarms and also to see
significant context-sensitive data from the alarm points that may
include spectra, waveform statistical info, and the like.
[0457] In embodiments, a relational database server ("RDS") 5930
may be used to access all of the information from a MMP and PCSA
information store 5932. As with the PARA server 5800 (FIG. 36),
information from the information store 5932 may be used with an EP
and align module 5934, a data exchange 5938 and the expert system
5940. In embodiments, a raw data stream archive 5942 and extract
and process raw data archive 5944 may also be used by the EP align
5934, the data exchange 5938 and the expert system 5940 as with the
PARA server 5800. In embodiments, new stream raw data 5950, new
extract and process raw data 5952, and new data 5954 (essentially
all other raw data such as overalls, smart bands, stats, and data
from the information store 5932) are directed by the CDMS 5832.
[0458] In embodiments, the streaming data may be linked with the
RDS 5930 and the MMP and PCSA information store 5932 using a
technical data management streaming ("TDMS") file format. In
embodiments, the information store 5932 may include tables for
recording at least portions of all measurement events. By way of
these examples, a measurement event may be any single data capture,
a stream, a snapshot, an averaged level, or an overall level. Each
of the measurement events in addition to point identification
information may also have a date and time stamp. In embodiments, a
link may be made between the streaming data, the measurement event,
and the tables in the information store 5932 using the TDMS format.
By way of these examples, the link may be created by storing unique
measurement point identification codes with a file structure having
the TDMS format by including and assigning TDMS properties. In
embodiments, a file with the TDMS format may allow for three levels
of hierarchy. By way of these examples, the three levels of
hierarchy may be root, group, and channel. It will be appreciated
in light of the disclosure that the Mimosa.TM. database schema may
be, in theory, unlimited. With that said, there are advantages to
limited TDMS hierarchies. In the many examples, the following
properties may be proposed for adding to the TDMS Stream structure
while using a Mimosa Compatible database schema.
[0459] Root Level: Global ID 1: Text String (This could be a unique
ID obtained from the web.); Global ID 2: Text String (This could be
an additional ID obtained from the web.); Company Name: Text
String; Company ID: Text String; Company Segment ID: 4-byte
Integer; Company Segment ID: 4-byte Integer; Site Name: Text
String; Site Segment ID: 4-byte Integer; Site Asset ID: 4-byte
Integer; Route Name: Text String; Version Number: Text String
[0460] Group Level: Section 1 Name: Text String; Section 1 Segment
ID: 4-byte Integer; Section 1 Asset ID: 4-byte Integer; Section 2
Name: Text String; Section 2 Segment ID: 4-byte Integer; Section 2.
Asset ID: 4-byte Integer; Machine Name: Text String; Machine
Segment ID: 4-byte Integer; Machine Asset ID: 4-byte Integer;
Equipment Name: Text String; Equipment Segment ID: 4-byte Integer;
Equipment Asset ID: 4-byte Integer; Shaft Name: Text String; Shaft
Segment ID: 4-byte Integer; Shaft Asset ID: 4-byte Integer; Bearing
Name: Text String; Bearing Segment ID: 4-byte Integer; Bearing
Asset ID: 4-byte Integer; Probe Name: Text String; Probe Segment
ID: 4-byte Integer; Probe Asset ID: 4-byte Integer
[0461] Channel Level: Channel #: 4-byte Integer; Direction: 4-byte
Integer (in certain examples may be text); Data Type: 4-byte
Integer; Reserved Name 1: Text String; Reserved Segment ID 1:
4-byte Integer; Reserved Name 2: Text String; Reserved Segment ID
2: 4-byte Integer; Reserved Name 3: Text String; Reserved Segment
ID 3: 4-byte Integer
[0462] In embodiments, the file with the TDMS format may
automatically use property or asset information and may make an
index file out of the specific property and asset information to
facilitate database searches, may offer a compromise for storing
voluminous streams of data because it may be optimized for storing
binary streams of data but may also include some minimal database
structure making many standard SQL operations feasible, but the
TDMS format and functionality discussed herein may not be as
efficient as a full-fledged SQL relational database. The TDMS
format, however, may take advantage of both worlds in that it may
balance between the class or format of writing and storing large
streams of binary data efficiently and the class or format of a
fully relational database, which facilitates searching, sorting and
data retrieval. In embodiments, an optimum solution may be found in
that metadata required for analytical purposes and extracting
prescribed lists with panel conditions for stream collection may be
stored in the RDS 5930 by establishing a link between the two
database methodologies. By way of these examples, relatively large
analog data streams may be stored predominantly as binary storage
in the raw data stream archive 5942 for rapid stream loading but
with inherent relational SQL type hooks, formats, conventions, or
the like. The files with the TDMS format may also be configured to
incorporate DIAdem.TM. reporting capability of LabVIEW.TM. software
in order to provide a further mechanism to conveniently and rapidly
facilitate accessing the analog or the streaming data.
[0463] The methods and systems disclosed herein may include,
connect to, or be integrated with a virtual data acquisition
instrument and in the many embodiments, FIG. 37 shows methods and
systems that include a virtual streaming DAQ instrument 6000 also
known as a virtual DAQ instrument, a VRDS, or a VSDAQ. In contrast
to the DAQ instrument 5002 (FIG. 22), the virtual DAQ instrument
6000 may be configured so to only include one native application.
In the many examples, the one permitted and one native application
may be the DAQ driver module 6002 that may manage all
communications with the DAQ Device 6004 which may include streaming
capabilities. In embodiments, other applications, if any, may be
configured as thin client web applications such as RESTful.TM. web
services. The one native application, or other applications or
services, may be accessible through the DAQ Web API 6010. The DAQ
Web API 6010 may run in or be accessible through various web
browsers.
[0464] In embodiments, storage of streaming data, as well as the
extraction and processing of streaming data into extract and
process data, may be handled primarily by the DAQ driver services
6012 under the direction of the DAQ Web API 6010. In embodiments,
the output from sensors of various types including vibration,
temperature, pressure, ultrasound and so on may be fed into the
instrument inputs of the DAQ device 6004. In embodiments, the
signals from the output sensors may be signal conditioned with
respect to scaling and filtering and digitized with an analog to a
digital converter. In embodiments, the signals from the output
sensors may be signals from all relevant channels simultaneously
sampled at a rate sufficient to perform the maximum desired
frequency analysis. In embodiments, the signals from the output
sensors may be sampled for a relatively long time, gap-free, as one
continuous stream so as to enable a wide array of further
post-processing at lower sampling rates with sufficient samples. In
further examples, streaming frequency may be adjusted (and
readjusted) to record streaming data at non-evenly spaced
recording. For temperature data, pressure data, and other similar
data that may be relatively slow, varying delta times between
samples may further improve quality of the data. By way of the
above examples, data may be streamed from a collection of points
and then the next set of data may be collected from additional
points according to a prescribed sequence, route, path, or the
like. In the many examples, the portable sensors may be moved to
the next location according to the prescribed sequence but not
necessarily all of them as some may be used for reference phase or
otherwise. In further examples, a multiplexer 6020 may be used to
switch to the next collection of points or a mixture of the two
methods may be combined.
[0465] In embodiments, the sequence and panel conditions that may
be used to govern the data collection process using the virtual DAQ
instrument 6000 may be obtained from the MMP PCSA information store
6022. The MMP PCSA information store 6022 may include such items as
the hierarchical structural relationships of the machine, i.e., a
machine contains pieces of equipment in which each piece of
equipment contains shafts and each shaft is associated with
bearings, which may be monitored by specific types of transducers
or probes according to a specific prescribed sequence (routes,
path, etc.) with specific panel conditions. By way of these
examples, the panel conditions may include hardware specific switch
settings or other collection parameters such as sampling rate,
AC/DC coupling, voltage range and gain, integration, high and low
pass filtering, anti-aliasing filtering, ICP.TM. transducers and
other integrated-circuit piezoelectric transducers, 4-20 mA loop
sensors, and the like. The information store 6022 includes other
information that may be stored in what would be machinery specific
features that would be important for proper analysis including the
number of gear teeth for a gear, the number of blades in a pump
impeller, the number of motor rotor bars, bearing specific
parameters necessary for calculating bearing frequencies, 1.times.
rotating speed (RPMs) of all rotating elements, and the like.
[0466] Upon direction of the DAQ Web API 6010 software, digitized
waveforms may be uploaded using the DAQ driver services 6012 of the
virtual DAQ instrument 6000. In embodiments, data may then be fed
into an RLN data and control server 6030 that may store the stream
data into a network stream data repository 6032. Unlike the DAQ
instrument 5002, the server 6030 may run from within the DAQ driver
module 6002. It will be appreciated in light of the disclosure that
a separate application may require drivers for running in the
native operating system and for this instrument only the instrument
driver may run natively. In many examples, all other applications
may be configured to be browser based. As such, a relevant network
variable may be very similar to a LabVIEW.TM. shared or network
stream variable which may be designed to be accessed over one or
more networks or via web applications.
[0467] In embodiments, the DAQ web API 6010 may also direct the
local data control application 6034 to extract and process the
recently obtained streaming data and, in turn, convert it to the
same or lower sampling rates of sufficient length to provide the
desired resolution. This data may be converted to spectra, then
averaged and processed in a variety of ways and stored as EP data,
such as on an EP data repository 6040. The EP data repository 6040
may, in certain embodiments, only be meant for temporary storage.
It will be appreciated in light of the disclosure that legacy data
may require its own sampling rates and resolution and often this
sampling rate may not be integer proportional to the acquired
sampling rate especially for order-sampled data whose sampling
frequency is related directly to an external frequency. The
external frequency may typically be the miming speed of the machine
or its internal componentry, rather than the more-standard sampling
rates produced by the internal crystals, clock functions, and the
like of the (e.g., values of Fmax of 100, 200, 500, 1K, 2K, 5K,
10K, 20K and so on) of the DAQ instrument 5002, 6000. In
embodiments, the EP align component of the local data control
application 6034 is able to fractionally adjust the sampling rate
to the non-integer ratio rates that may be more applicable to
legacy data sets and therefore drive compatibility with legacy
systems. In embodiments, the fractional rates may be converted to
integer ratio rates more readily because the length of the data to
be processed (or at least that portion of the greater stream of
data) is adjustable because of the depth and content of the
original acquired streaming data by the DAQ instrument 5002, 6000.
It will be appreciated in light of the disclosure that if the data
was not streamed and just stored as traditional snap-shots of
spectra with the standard values of Fmax, it may very well be
impossible to retroactively and accurately convert the acquired
data to the order-sampled data. In embodiments, the stream data may
be converted, especially for legacy data purposes, to the proper
sampling rate and resolution as described and stored in the EP
legacy data repository 6042. To support legacy data identification
scenarios, a user input 6044 may be included if there is no
automated process for identification translation. In embodiments,
one such automated process for identification translation may
include importation of data from a legacy system that may contain a
fully standardized format such as the Mimosa.TM. format and
sufficient identification information to complete an ID Mapping
Table 6048. In further examples, the end user, a legacy data
vendor, a legacy data storage facility, or the like may be able to
supply enough info to complete (or sufficiently complete) relevant
portions of the ID Mapping Table 6048 to provide, in turn, the
database schema for the raw data of the legacy system so it may be
readily ingested, saved, and used for analytics in the current
systems disclosed herein.
[0468] FIG. 38 depicts further embodiments and details of the
virtual DAQ Instrument 6000. In these examples, the DAQ Web API
6010 may control the data collection process as well as its
sequence. The DAQ Web API 6010 may provide the capability for
editing this process, viewing plots of the data, controlling the
processing of that data and viewing the output in all its myriad
forms, analyzing the data, including the expert analysis,
communicating with external devices via the DAQ driver module 6002,
as well as communicating with and transferring both streaming data
and EP data to one or more cloud network facilities 5080 whenever
possible. In embodiments, the virtual DAQ instrument itself and the
DAQ Web API 6010 may run independently of access to cloud network
facilities 5080 when local demands may require or simply as a
result of there being no outside connectivity such use throughout a
proprietary industrial setting that prevents such signals. In
embodiments, the DAQ Web API 6010 may also govern the movement of
data, its filtering, as well as many other housekeeping
functions.
[0469] The virtual DAQ Instrument 6000 may also include an expert
analysis module 6052. In embodiments, the expert analysis module
6052 may be a web application or other suitable module that may
generate reports 6054 that may use machine or measurement point
specific information from the MMP PCSA information store 6022 to
analyze stream data 6058 using the stream data analyzer module
6050. In embodiments, supervisory control of the module 6052 may be
provided by the DAQ Web API 6010. In embodiments, the expert
analysis may also be supplied (or supplemented) via the expert
system module 5940 that may be resident on one or more cloud
network facilities that are accessible via the CDMS 5832. In many
examples, expert analysis via the cloud may be preferred over local
systems such as expert analysis module 6052 for various reasons,
such as the availability and use of the most up-to-date software
version, more processing capability, a bigger volume of historical
data to reference and the like. It will be appreciated in light of
the disclosure that it may be important to offer expert analysis
when an internet connection cannot be established so as to provide
a redundancy, when needed, for seamless and time efficient
operation. In embodiments, this redundancy may be extended to all
of the discussed modular software applications and databases where
applicable so each module discussed herein may be configured to
provide redundancy to continue operation in the absence of an
internet connection.
[0470] FIG. 39 depicts further embodiments and details of many
virtual DAQ instruments existing in an online system and connecting
through network endpoints through a central DAQ instrument to one
or more cloud network facilities. In embodiments, a master DAQ
instrument with network endpoint 6060 is provided along with
additional DAQ instruments such as a DAQ instrument with network
endpoint 6062, a DAQ instrument with network endpoint 6064, and a
DAQ instrument with network endpoint 6068. The master DAQ
instrument with network endpoint 6060 may connect with the other
DAQ instruments with network endpoints 6062, 6064, 6068 over LAN
6070. It will be appreciated that each of the instruments 6060,
6062, 6064, 6068 may include personal computer, a connected device,
or the like that include Windows.TM., Linux.TM., or other suitable
operating systems to facilitate ease of connection of devices
utilizing many wired and wireless network options such as Ethernet,
wireless 802.11g, 900 MHz wireless (e.g., for better penetration of
walls, enclosures and other structural barriers commonly
encountered in an industrial setting), as well as a myriad of other
things permitted by the use of off-the-shelf communication hardware
when needed.
[0471] FIG. 40 depicts further embodiments and details of many
functional components of an endpoint that may be used in the
various settings, environments, and network connectivity settings.
The endpoint includes endpoint hardware modules 6080. In
embodiments, the endpoint hardware modules 6080 may include one or
more multiplexers 6082, a DAQ instrument 6084, as well as a
computer 6088, computing device, PC, or the like that may include
the multiplexers, DAQ instruments, and computers, connected devices
and the like, as disclosed herein. The endpoint software modules
6090 include a data collector application (DCA) 6092 and a raw data
server (RDS) 6094. In embodiments, DCA 6092 may be similar to the
DAQ API 5052 (FIG. 22) and may be configured to be responsible for
obtaining stream data from the DAQ device 6084 and storing it
locally according to a prescribed sequence or upon user directives.
In the many examples, the prescribed sequence or user directives
may be a LabVIEW.TM. software app that may control and read data
from the DAQ instruments. For cloud based online systems, the
stored data in many embodiments may be network accessible. In many
examples, LabVIEW.TM. tools may be used to accomplish this with a
shared variable or network stream (or subsets of shared variables).
Shared variables and the affiliated network streams may be network
objects that may be optimized for sharing data over the network. In
many embodiments, the DCA 6092 may be configured with a graphic
user interface that may be configured to collect data as
efficiently and fast as possible and push it to the shared variable
and its affiliated network stream. In embodiments, the endpoint raw
data server 6094 may be configured to read raw data from the
single-process shared variable and may place it with a master
network stream. In embodiments, a raw stream of data from portable
systems may be stored locally and temporarily until the raw stream
of data is pushed to the MRDS 5082 (FIG. 22). It will be
appreciated in light of the disclosure that on-line system
instruments on a network can be termed endpoints whether local or
remote or associated with a local area network or a wide area
network. For portable data collector applications that may or may
not be wirelessly connected to one or more cloud network
facilities, the endpoint term may be omitted as described so as to
detail an instrument that may not require network connectivity.
[0472] FIG. 41 depicts further embodiments and details of multiple
endpoints with their respective software blocks with at least one
of the devices configured as master blocks. Each of the blocks may
include a data collector application ("DCA") 7000 and a raw data
server ("RDS") 7002. In embodiments, each of the blocks may also
include a master raw data server module ("MRDS") 7004, a master
data collection and analysis module ("MDCA") 7008, and a
supervisory and control interface module ("SCI") 7010. The MRDS
7004 may be configured to read network stream data (at a minimum)
from the other endpoints and may forward it up to one or more cloud
network facilities via the CDMS 5832 including the cloud services
5890 and the cloud data 5892. In embodiments, the CDMS 5832 may be
configured to store the data and to provide web, data, and
processing services. In these examples, this may be implemented
with a LabVIEW.TM. application that may be configured to read data
from the network streams or share variables from all of the local
endpoints, write them to the local host PC, local computing device,
connected device, or the like, as both a network stream and file
with TDMS.TM. formatting. In embodiments, the CDMS 5832 may also be
configured to then post this data to the appropriate buckets using
the LabVIEW or similar software that may be supported by S3.TM. web
service from the Amazon Web Services ("AWS.TM.") on the Amazon.TM.
web server, or the like and may effectively serve as a back-end
server. In the many examples, different criteria may be enabled or
may be set up for when to post data, create or adjust schedules,
create or adjust event triggering including a new data event,
create a buffer full message, create or more alarms messages, and
the like.
[0473] In embodiments, the MDCA 7008 may be configured to provide
automated as well as user-directed analyses of the raw data that
may include tracking and annotating specific occurrence and in
doing so, noting where reports may be generated and alarms may be
noted. In embodiments, the SCI 7010 may be an application
configured to provide remote control of the system from the cloud
as well as the ability to generate status and alarms. In
embodiments, the SCI 7010 may be configured to connect to,
interface with, or be integrated into a supervisory control and
data acquisition ("SCADA") control system. In embodiments, the SCI
7010 may be configured as a LabVIEW.TM. application that may
provide remote control and status alerts that may be provided to
any remote device that may connect to one or more of the cloud
network facilities 5870.
[0474] In embodiments, the equipment that is being monitored may
include RFID tags that may provide vital machinery analysis
background information. The RFID tags may be associated with the
entire machine or associated with the individual componentry and
may be substituted when certain parts of the machine are replaced,
repaired, or rebuilt. The RFID tags may provide permanent
information relevant to the lifetime of the unit or may also be
re-flashed to update with at least a portion of new information. In
many embodiments, the DAQ instruments 5002 disclosed herein may
interrogate the one or more RFID chips to learn of the machine, its
componentry, its service history, and the hierarchical structure of
how everything is connected including drive diagrams, wire
diagrams, and hydraulic layouts. In embodiments, some of the
information that may be retrieved from the RFID tags includes
manufacturer, machinery type, model, serial number, model number,
manufacturing date, installation date, lots numbers, and the like.
By way of these examples, machinery type may include the use of a
Mimosa.TM. format table including information about one or more of
the following motors, gearboxes, fans, and compressors. The
machinery type may also include the number of bearings, their type,
their positioning, and their identification numbers. The
information relevant to one or more fans includes fan type, number
of blades, number of vanes, and number of belts. It will be
appreciated in light of the disclosure that other machines and
their componentry may be similarly arranged hierarchically with
relevant information all of which may be available through
interrogation of one or more RFID chips associated with the one or
more machines.
[0475] In embodiments, data collection in an industrial environment
may include routing analog signals from a plurality of sources,
such as analog sensors, to a plurality of analog signal processing
circuits. Routing of analog signals may be accomplished by an
analog crosspoint switch that may route any of a plurality of
analog input signals to any of a plurality of outputs, such as to
analog and/or digital outputs. Routing of inputs to outputs in an
analog signal crosspoint switch in an industrial environment may be
configurable, such as by an electronic signal to which a switch
portion of the analog crosspoint switch is responsive.
[0476] In embodiments, the analog crosspoint switch may receive
analog signals from a plurality of analog signal sources in the
industrial environment. Analog signal sources may include sensors
that produce an analog signal. Sensors that produce an analog
signal that may be switched by the analog crosspoint switch may
include sensors that detect a condition and convert it to an analog
signal that may be representative of the condition, such as
converting a condition to a corresponding voltage. Exemplary
conditions that may be represented by a variable voltage may
include temperature, friction, sound, light, torque,
revolutions-per-minute, mechanical resistance, pressure, flow rate,
and the like, including any of the conditions represented by inputs
sources and sensors disclosed throughout this disclosure and the
documents incorporated herein by reference. Other forms of analog
signal may include electrical signals, such as variable voltage,
variable current, variable resistance, and the like.
[0477] In embodiments, the analog crosspoint switch may preserve
one or more aspects of an analog signal being input to it in an
industrial environment. Analog circuits integrated into the switch
may provide buffered outputs. The analog circuits of the analog
crosspoint switch may follow an input signal, such as an input
voltage to produce a buffered representation on an output. This may
alternatively be accomplished by relays (mechanical, solid state,
and the like) that allow an analog voltage or current present on an
input to propagate to a selected output of the analog switch.
[0478] In embodiments, an analog crosspoint switch in an industrial
environment may be configured to switch any of a plurality of
analog inputs to any of a plurality of analog outputs. An example
embodiment includes a MIMO, multiplexed configuration. An analog
crosspoint switch may be dynamically configurable so that changes
to the configuration causes a change in the mapping of inputs to
outputs. A configuration change may apply to one or more mappings
so that a change in mapping may result in one or more of the
outputs being mapped to different input than before the
configuration change.
[0479] In embodiments, the analog crosspoint switch may have more
inputs than outputs, so that only a subset of inputs can be routed
to outputs concurrently. In other embodiments, the analog
crosspoint switch may have more outputs than inputs, so that either
a single input may be made available currently on multiple outputs,
or at least one output may not be mapped to any input.
[0480] In embodiments, an analog crosspoint switch in an industrial
environment may be configured to switch any of a plurality of
analog inputs to any of a plurality of digital outputs. To
accomplish conversion from analog inputs to digital outputs, an
analog-to-digital converter circuit may be configured on each
input, each output, or at intermediate points between the input(s)
and output(s) of the analog crosspoint switch. Benefits of
including digitization of analog signals in an analog crosspoint
switch that may be located close to analog signal sources may
include reducing signal transport costs and complexity that digital
signal communication has over analog, reducing energy consumption,
facilitating detection and regulation of aberrant conditions before
they propagate throughout an industrial environment, and the like.
Capturing analog signals close to their source may also facilitate
improved signal routing management that is more tolerant of real
world effects such as requiring that multiple signals be routed
simultaneously. In this example, a portion of the signals can be
captured (and stored) locally while another portion can be
transferred through the data collection network. Once the data
collection network has available bandwidth, the locally stored
signals can be delivered, such as with a time stamp indicating the
time at which the data was collected. This technique may be useful
for applications that have concurrent demand for data collection
channels that exceed the number of channels available. Sampling
control may also be based on an indication of data worth sampling.
As an example, a signal source, such as a sensor in an industrial
environment may provide a data valid signal that transmits an
indication of when data from the sensor is available.
[0481] In embodiments, mapping inputs of the analog crosspoint
switch to outputs may be based on a signal route plan for a portion
of the industrial environment that may be presented to the
crosspoint switch. The signal route plan may be used in a method of
data collection in the industrial environment that may include
routing a plurality of analog signals along a plurality of analog
signal paths. The method may include connecting the plurality of
analog signals individually to inputs of the analog crosspoint
switch that may be configured with a route plan. The crosspoint
switch may, responsively to the configured route plan, route a
portion of the plurality of analog signals to a portion of the
plurality of analog signal paths.
[0482] In embodiments, the analog crosspoint switch may include at
least one high current output drive circuit that may be suitable
for routing the analog signal along a path that requires high
current. In embodiments, the analog crosspoint switch may include
at least one voltage-limited input that may facilitate protecting
the analog crosspoint switch from damage due to excessive analog
input signal voltage. In embodiments, the analog crosspoint switch
may include at least one current limited input that may facilitate
protecting the analog crosspoint switch from damage due to
excessive analog input current. The analog crosspoint switch may
comprise a plurality of interconnected relays that may facilitate
routing the input(s) to the output(s) with little or no substantive
signal loss.
[0483] In embodiments, an analog crosspoint switch may include
processing functionality, such as signal processing and the like
(e.g., a programmed processor, special purpose processor, a digital
signal processor, and the like) that may detect one or more analog
input signal conditions. In response to such detection, one or more
actions may be performed, such as setting an alarm, sending an
alarm signal to another device in the industrial environment,
changing the crosspoint switch configuration, disabling one or more
outputs, powering on or off a portion of the switch, changing a
state of an output, such as a general purpose digital or analog
output, and the like. In embodiments, the switch may be configured
to process inputs for producing a signal on one or more of the
outputs. The inputs to use, processing algorithm for the inputs,
condition for producing the signal, output to use, and the like may
be configured in a data collection template.
[0484] In embodiments, an analog crosspoint switch may comprise
greater than 32 inputs and greater than 32 outputs. A plurality of
analog crosspoint switches may be configured so that even though
each switch offers fewer than 32 inputs and 32 outputs it may be
configured to facilitate switching any of 32 inputs to any of 32
outputs spread across the plurality of crosspoint switches.
[0485] In embodiments, an analog crosspoint switch suitable for use
in an industrial environment may comprise four or fewer inputs and
four or fewer outputs. Each output may be configurable to produce
an analog output that corresponds to the mapped analog input or it
may be configured to produce a digital representation of the
corresponding mapped input.
[0486] In embodiments, an analog crosspoint switch for use in an
industrial environment may be configured with circuits that
facilitate replicating at least a portion of attributes of the
input signal, such as current, voltage range, offset, frequency,
duty cycle, ramp rate, and the like while buffering (e.g.,
isolating) the input signal from the output signal. Alternatively,
an analog crosspoint switch may be configured with unbuffered
inputs/outputs, thereby effectively producing a bi-directional
based crosspoint switch).
[0487] In embodiments, an analog crosspoint switch for use in an
industrial environment may include protected inputs that may be
protected from damaging conditions, such as through use of signal
conditioning circuits. Protected inputs may prevent damage to the
switch and to downstream devices to which the switch outputs
connect. As an example, inputs to such an analog crosspoint switch
may include voltage clipping circuits that prevent a voltage of an
input signal from exceeding an input protection threshold. An
active voltage adjustment circuit may scale an input signal by
reducing it uniformly so that a maximum voltage present on the
input does not exceed a safe threshold value. As another example,
inputs to such an analog crosspoint switch may include current
shunting circuits that cause current beyond a maximum input
protection current threshold to be diverted through protection
circuits rather than enter the switch. Analog switch inputs may be
protected from electrostatic discharge and/or lightning strikes.
Other signal conditioning functions that may be applied to inputs
to an analog crosspoint switch may include voltage scaling
circuitry that attempts to facilitate distinguishing between valid
input signals and low voltage noise that may be present on the
input. However, in embodiments, inputs to the analog crosspoint
switch may be unbuffered and/or unprotected to make the least
impact on the signal. Signals such as alarm signals, or signals
that cannot readily tolerate protection schemes, such as those
schemes described above herein may be connected to unbuffered
inputs of the analog crosspoint switch.
[0488] In embodiments, an analog crosspoint switch may be
configured with circuitry, logic, and/or processing elements that
may facilitate input signal alarm monitoring. Such an analog
crosspoint switch may detect inputs meeting alarm conditions and in
response thereto, switch inputs, switch mapping of inputs to
outputs, disable inputs, disable outputs, issue an alarm signal,
activate/deactivate a general-purpose output, or the like.
[0489] In embodiments, a system for collecting data in an
industrial environment may include an analog crosspoint switch that
may be adapted to selectively power up or down portions of the
analog crosspoint switch or circuitry associated with the analog
crosspoint switch, such as input protection devices, input
conditioning devices, switch control devices and the like. Portions
of the analog crosspoint switch that may be powered on/off may
include outputs, inputs, sections of the switch and the like. In an
example, an analog crosspoint switch may include a modular
structure that may separate portions of the switch into
independently powered sections. Based on conditions, such as an
input signal meeting a criterion or a configuration value being
presented to the analog crosspoint switch, one or more modular
sections may be powered on/off.
[0490] In embodiments, a system for collecting data in an
industrial environment may include an analog crosspoint switch that
may be adapted to perform signal processing including, without
limitation, providing a voltage reference for detecting an input
crossing the voltage reference (e.g., zero volts for detecting
zero-crossing signals), a phase-lock loop to facilitate capturing
slow frequency signals (e.g., low-speed revolution-per-minute
signals and detecting their corresponding phase), deriving input
signal phase relative to other inputs, deriving input signal phase
relative to a reference (e.g., a reference clock), deriving input
signal phase relative to detected alarm input conditions and the
like. Other signal processing functions of such an analog
crosspoint switch may include oversampling of inputs for
delta-sigma A/D, to produce lower sampling rate outputs, to
minimize AA filter requirements and the like. Such an analog
crosspoint switch may support long block sampling at a constant
sampling rate even as inputs are switched, which may facilitate
input signal rate independence and reduce complexity of sampling
scheme(s). A constant sampling rate may be selected from a
plurality of rates that may be produced by a circuit, such as a
clock divider circuit that may make available a plurality of
components of a reference clock.
[0491] In embodiments, a system for collecting data in an
industrial environment may include an analog crosspoint switch that
may be adapted to support implementing data collection/data routing
templates in the industrial environment. The analog crosspoint
switch may implement a data collection/data routing template based
on conditions in the industrial environment that it may detect or
derive, such as an input signal meeting one or more criteria (e.g.,
transition of a signal from a first condition to a second, lack of
transition of an input signal within a predefined time interface
(e.g., inactive input) and the like).
[0492] In embodiments, a system for collecting data in an
industrial environment may include an analog crosspoint switch that
may be adapted to be configured from a portion of a data collection
template. Configuration may be done automatically (without needing
human intervention to perform a configuration action or change in
configuration), such as based on a time parameter in the template
and the like. Configuration may be done remotely, e.g., by sending
a signal from a remote location that is detectable by a switch
configuration feature of the analog crosspoint switch.
Configuration may be done dynamically, such as based on a condition
that is detectable by a configuration feature of the analog
crosspoint switch (e.g., a timer, an input condition, an output
condition, and the like). In embodiments, information for
configuring an analog crosspoint switch may be provided in a
stream, as a set of control lines, as a data file, as an indexed
data set, and the like. In embodiments, configuration information
in a data collection template for the switch may include a list of
each input and a corresponding output, a list of each output
function (active, inactive, analog, digital and the like), a
condition for updating the configuration (e.g., an input signal
meeting a condition, a trigger signal, a time (relative to another
time/event/state, or absolute), a duration of the configuration,
and the like. In embodiments, configuration of the switch may be
input signal protocol aware so that switching from a first input to
a second input for a given output may occur based on the protocol.
In an example, a configuration change may be initiated with the
switch to switch from a first video signal to a second video
signal. The configuration circuitry may detect the protocol of the
input signal and switch to the second video signal during a
synchronization phase of the video signal, such as during
horizontal or vertical refresh. In other examples, switching may
occur when one or more of the inputs are at zero volts. This may
occur for a sinusoidal signal that transitions from below zero
volts to above zero volts.
[0493] In embodiments, a system for collecting data in an
industrial environment may include an analog crosspoint switch that
may be adapted to provide digital outputs by converting analog
signals input to the switch into digital outputs. Converting may
occur after switching the analog inputs based on a data collection
template and the like. In embodiments, a portion of the switch
outputs may be digital and a portion may be analog. Each output, or
groups thereof, may be configurable as analog or digital, such as
based on analog crosspoint switch output configuration information
included in or derived from a data collection template. Circuitry
in the analog crosspoint switch may sense an input signal voltage
range and intelligently configure an analog-to-digital conversion
function accordingly. As an example, a first input may have a
voltage range of 12 volts and a second input may have a voltage
range of 24 volts. Analog-to-digital converter circuits for these
inputs may be adjusted so that the full range of the digital value
(e.g., 256 levels for an 8-bit signal) will map substantially
linearly to 12 volts for the first input and 24 volts for the
second input.
[0494] In embodiments, an analog crosspoint switch may
automatically configure input circuitry based on characteristics of
a connected analog signal. Examples of circuitry configuration may
include setting a maximum voltage, a threshold based on a sensed
maximum threshold, a voltage range above and/or below a ground
reference, an offset reference, and the like. The analog crosspoint
switch may also adapt inputs to support voltage signals, current
signals, and the like. The analog crosspoint switch may detect a
protocol of an input signal, such as a video signal protocol, audio
signal protocol, digital signal protocol, protocol based on input
signal frequency characteristics, and the like. Other aspects of
inputs of the analog crosspoint switch that may be adapted based on
the incoming signal may include a duration of sampling of the
signal, and comparator or differential type signals, and the
like.
[0495] In embodiments, an analog crosspoint switch may be
configured with functionality to counteract input signal drift
and/or leakage that may occur when an analog signal is passed
through it over a long period of time without changing value (e.g.,
a constant voltage). Techniques may include voltage boost, current
injection, periodic zero referencing (e.g., temporarily connecting
the input to a reference signal, such as ground, applying a high
resistance pathway to the ground reference, and the like).
[0496] In embodiments, a system for data collection in an
industrial environment may include an analog crosspoint switch
deployed in an assembly line comprising conveyers and/or lifters. A
power roller conveyor system includes many rollers that deliver
product along a path. There may be many points along the path that
may be monitored for proper operation of the rollers, load being
placed on the rollers, accumulation of products, and the like. A
power roller conveyor system may also facilitate moving product
through longer distances and therefore may have a large number of
products in transport at once. A system for data collection in such
an assembly environment may include sensors that detect a wide
range of conditions as well as at a large number of positions along
the transport path. As a product progresses down the path, some
sensors may be active and others, such as those that the product
has passed maybe inactive. A data collection system may use an
analog crosspoint switch to select only those sensors that are
currently or anticipated to be active by switching from inputs that
connect to inactive sensors to those that connect to active sensors
and thereby provide the most useful sensor signals to data
detection and/or collection and/or processing facilities. In
embodiments, the analog crosspoint switch may be configured by a
conveyor control system that monitors product activity and
instructs the analog crosspoint switch to direct different inputs
to specific outputs based on a control program or data collection
template associated with the assembly environment.
[0497] In embodiments, a system for data collection in an
industrial environment may include an analog crosspoint switch
deployed in a factory comprising use of fans as industrial
components. In embodiments, fans in a factory setting may provide a
range of functions including drying, exhaust management, clean air
flow and the like. In an installation of a large number of fans,
monitoring fan rotational speed, torque, and the like may be
beneficial to detect an early indication of a potential problem
with air flow being produced by the fans. However, concurrently
monitoring each of these elements for a large number of fans may be
inefficient. Therefore, sensors, such as tachometers, torque
meters, and the like may be disposed at each fan and their analog
output signal(s) may be provided to an analog crosspoint switch.
With a limited number of outputs, or at least a limited number of
systems that can process the sensor data, the analog crosspoint
switch may be used to select among the many sensors and pass along
a subset of the available sensor signals to data collection,
monitoring, and processing systems. In an example, sensor signals
from sensors disposed at a group of fans may be selected to be
switched onto crosspoint switch outputs. Upon satisfactory
collection and/or processing of the sensor signals for this group
of fans, the analog crosspoint switch may be reconfigured to switch
signals from another group of fans to be processed.
[0498] In embodiments, a system for data collection in an
industrial environment may include an analog crosspoint switch
deployed as an industrial component in a turbine-based power
system. Monitoring for vibration in turbine systems, such as
hydro-power systems, has been demonstrated to provide advantages in
reduction in down time. However, with a large number of areas to
monitor for vibration, particularly for on-line vibration
monitoring, including relative shaft vibration, bearings absolute
vibration, turbine cover vibration, thrust bearing axial vibration,
stator core vibrations, stator bar vibrations, stator end winding
vibrations, and the like, it may be beneficial to select among this
list over time, such as taking samples from sensors for each of
these types of vibration a few at a time. A data collection system
that includes an analog crosspoint switch may provide this
capability by connecting each vibration sensor to separate inputs
of the analog crosspoint switch and configuring the switch to
output a subset of its inputs. A vibration data processing system,
such as a computer, may determine which sensors to pass through the
analog crosspoint switch and configure an algorithm to perform the
vibration analysis accordingly. As an example, sensors for
capturing turbine cover vibration may be selected in the analog
crosspoint switch to be passed on to a system that is configured
with an algorithm to determine turbine cover vibration from the
sensor signals. Upon completion of determining turbine cover
vibration, the crosspoint switch may be configured to pass along
thrust bearing axial vibration sensor signals and a corresponding
vibration analysis algorithm may be applied to the data. In this
way, each type of vibration may be analyzed by a single processing
system that works cooperatively with an analog crosspoint switch to
pass specific sensor signals for processing.
[0499] Referring to FIG. 44, an analog crosspoint switch for
collecting data in an industrial environment is depicted. The
analog crosspoint switch 7022 may have a plurality of inputs 7024
that connect to sensors 7026 in the industrial environment. The
analog crosspoint switch 7022 may also comprise a plurality of
outputs 7028 that connect to data collection infrastructure, such
as analog-to-digital converters 7030, analog comparators 7032, and
the like. The analog crosspoint switch 7022 may facilitate
connecting one or more inputs 7024 to one or more outputs 7028 by
interpreting a switch control value that may be provided to it by a
controller 7034 and the like.
[0500] An example system for data collection in an industrial
environment comprising includes analog signal sources that each
connect to at least one input of an analog crosspoint switch
including a plurality of inputs and a plurality of outputs; where
the analog crosspoint switch is configurable to switch a portion of
the input signal sources to a plurality of the outputs.
[0501] 2. In certain embodiments, the analog crosspoint switch
further includes an analog-to-digital converter that converts a
portion of analog signals input to the crosspoint switch into
representative digital signals; a portion of the outputs including
analog outputs and a portion of the outputs comprises digital
outputs; and/or where the analog crosspoint switch is adapted to
detect one or more analog input signal conditions. Any one or more
of the example embodiments include the analog input signal
conditions including a voltage range of the signal, and where the
analog crosspoint switch responsively adjusts input circuitry to
comply with detected voltage range.
[0502] An example system of data collection in an industrial
environment includes a number of industrial sensors that produce
analog signals representative of a condition of an industrial
machine in the environment being sensed by the number of industrial
sensors, a crosspoint switch that receives the analog signals and
routes the analog signals to separate analog outputs of the
crosspoint switch based on a signal route plan presented to the
crosspoint switch. In certain embodiments, the analog crosspoint
switch further includes an analog-to-digital converter that
converts a portion of analog signals input to the crosspoint switch
into representative digital signals; where a portion of the outputs
include analog outputs and a portion of the outputs include digital
outputs; where the analog crosspoint switch is adapted to detect
one or more analog input signal conditions; where the one or more
analog input signal conditions include a voltage range of the
signal, and/or where the analog crosspoint switch responsively
adjusts input circuitry to comply with detected voltage range.
[0503] An example method of data collection in an industrial
environment includes routing a number of analog signals along a
plurality of analog signal paths by connecting the plurality of
analog signals individually to inputs of an analog crosspoint
switch, configuring the analog crosspoint switch with data routing
information from a data collection template for the industrial
environment routing, and routing with the configured analog
crosspoint switch a portion of the number of analog signals to a
portion the plurality of analog signal paths. In certain further
embodiments, at least one output of the analog crosspoint switch
includes a high current driver circuit; at least one input of the
analog crosspoint switch includes a voltage limiting circuit;
and/or at least one input of the analog crosspoint switch includes
a current limiting circuit. In certain further embodiments, the
analog crosspoint switch includes a number of interconnected relays
that facilitate connecting any of a number of inputs to any of a
plurality of outputs; the analog crosspoint switch further
including an analog-to-digital converter that converts a portion of
analog signals input to the crosspoint switch into a representative
digital signal; the analog crosspoint switch further including
signal processing functionality to detect one or more analog input
signal conditions, and in response thereto, to perform an action
(e.g., set an alarm, change switch configuration, disable one or
more outputs, power off a portion of the switch, change a state of
a general purpose (digital/analog) output, etc.); where a portion
of the outputs are analog outputs and a portion of the outputs are
digital outputs; where the analog crosspoint switch is adapted to
detect one or more analog input signal conditions; where the analog
crosspoint switch is adapted to take one or more actions in
response to detecting the one or more analog input signal
conditions, the one more actions including setting an alarm,
sending an alarm signal, changing a configuration of the analog
crosspoint switch, disabling an output, powering off a portion of
the analog crosspoint switch, powering on a portion of the analog
crosspoint switch, and/or controlling a general purpose output of
the analog crosspoint switch.
[0504] An example system includes a power roller of a conveyor,
including any of the described operations of an analog crosspoint
switch. Without limitation, further example embodiments includes
sensing conditions of the power roller by the sensors to determine
a rate of rotation of the power roller, a load being transported by
the power roller, power being consumed by the power roller, and/or
a rate of acceleration of the power roller. An example system
includes a fan in a factory setting, including any of the described
operations of an analog crosspoint switch. Without limitation,
certain further embodiments include sensors disposed to sense
conditions of the fan, including a fan blade tip speed, torque,
back pressure, RPMs, and/or a volume of air per unit time displaced
by the fan. An example system includes a turbine in a power
generation environment, including any of the described operations
of an analog crosspoint switch. Without limitation, certain further
embodiments include a number of sensors disposed to sense
conditions of the turbine, where the sensed conditions include a
relative shaft vibration, an absolute vibration of bearings, a
turbine cover vibration, a thrust bearing axial vibration,
vibrations of stators or stator cores, vibrations of stator bars,
and/or vibrations of stator end windings.
[0505] In embodiments, methods and systems of data collection in an
industrial environment may include a plurality of industrial
condition sensing and acquisition modules that may include at least
one programmable logic component per module that may control a
portion of the sensing and acquisition functionality of its module.
The programmable logic components on each of the modules may be
interconnected by a dedicated logic bus that may include data and
control channels. The dedicated logic bus may extend logically
and/or physically to other programmable logic components on other
sensing and acquisition modules. In embodiments, the programmable
logic components may be programmed via the dedicated
interconnection bus, via a dedicated programming portion of the
dedicated interconnection bus, via a program that is passed between
programmable logic components, sensing and acquisition modules, or
whole systems. A programmable logic component for use in an
industrial environment data sensing and acquisition system may be a
Complex Programmable Logic Device, an Application-Specific
Integrated Circuit, microcontrollers, and combinations thereof.
[0506] A programmable logic component in an industrial data
collection environment may perform control functions associated
with data collection. Control examples include power control of
analog channels, sensors, analog receivers, analog switches,
portions of logic modules (e.g., a logic board, system, and the
like) on which the programmable logic component is disposed,
self-power-up/down, self-sleep/wake up, and the like. Control
functions, such as these and others, may be performed in
coordination with control and operational functions of other
programmable logic components, such as other components on a single
data collection module and components on other such modules. Other
functions that a programmable logic component may provide may
include generation of a voltage reference, such as a precise
voltage reference for input signal condition detection. A
programmable logic component may generate, set, reset, adjust,
calibrate, or otherwise determine the voltage of the reference, its
tolerance, and the like. Other functions of a programmable logic
component may include enabling a digital phase lock loop to
facilitate tracking slowly transitioning input signals, and further
to facilitate detecting the phase of such signals. Relative phase
detection may also be implemented, including phase relative to
trigger signals, other analog inputs, on-board references (e.g.,
on-board timers), and the like. A programmable logic component may
be programmed to perform input signal peak voltage detection and
control input signal circuitry, such as to implement auto-scaling
of the input to an operating voltage range of the input. Other
functions that may be programmed into a programmable logic
component may include determining an appropriate sampling frequency
for sampling inputs independently of their operating frequencies. A
programmable logic component may be programmed to detect a maximum
frequency among a plurality of input signals and set a sampling
frequency for each of the input signals that is greater than the
detected maximum frequency.
[0507] A programmable logic component may be programmed to
configure and control data routing components, such as
multiplexers, crosspoint switches, analog-to-digital converters,
and the like, to implement a data collection template for the
industrial environment. A data collection template may be included
in a program for a programmable logic component. Alternatively, an
algorithm that interprets a data collection template to configure
and control data routing resources in the industrial environment
may be included in the program.
[0508] In embodiments, one or more programmable logic components in
an industrial environment may be programmed to perform smart-band
signal analysis and testing. Results of such analysis and testing
may include triggering smart band data collection actions, that may
include reconfiguring one or more data routing resources in the
industrial environment. A programmable logic component may be
configured to perform a portion of smart band analysis, such as
collection and validation of signal activity from one or more
sensors that may be local to the programmable logic component.
Smart band signal analysis results from a plurality of programmable
logic components may be further processed by other programmable
logic components, servers, machine learning systems, and the like
to determine compliance with a smart band.
[0509] In embodiments, one or more programmable logic components in
an industrial environment may be programmed to control data routing
resources and sensors for outcomes, such as reducing power
consumption (e.g., powering on/off resources as needed),
implementing security in the industrial environment by managing
user authentication, and the like. In embodiments, certain data
routing resources, such as multiplexers and the like, may be
configured to support certain input signal types. A programmable
logic component may configure the resources based on the type of
signals to be routed to the resources. In embodiments, the
programmable logic component may facilitate coordination of sensor
and data routing resource signal type matching by indicating to a
configurable sensor a protocol or signal type to present to the
routing resource. A programmable logic component may facilitate
detecting a protocol of a signal being input to a data routing
resource, such as an analog crosspoint switch and the like. Based
on the detected protocol, the programmable logic component may
configure routing resources to facilitate support and efficient
processing of the protocol. In an example, a programmable logic
component configured data collection module in an industrial
environment may implement an intelligent sensor interface
specification, such as IEEE 1451.2 intelligent sensor interface
specification.
[0510] In embodiments, distributing programmable logic components
across a plurality of data sensing, collection, and/or routing
modules in an industrial environment may facilitate greater
functionality and local inter-operational control. In an example,
modules may perform operational functions independently based on a
program installed in one or more programmable logic components
associated with each module. Two modules may be constructed with
substantially identical physical components, but may perform
different functions in the industrial environment based on the
program(s) loaded into programmable logic component(s) on the
modules. In this way, even if one module were to experience a
fault, or be powered down, other modules may continue to perform
their functions due at least in part to each having its own
programmable logic component(s). In embodiments, configuring a
plurality of programmable logic components distributed across a
plurality of data collection modules in an industrial environment
may facilitate scalability in terms of conditions in the
environment that may be sensed, the number of data routing options
for routing sensed data throughout the industrial environment, the
types of conditions that may be sensed, the computing capability in
the environment, and the like.
[0511] In embodiments, a programmable logic controller-configured
data collection and routing system may facilitate validation of
external systems for use as storage nodes, such as for a
distributed ledger, and the like. A programmable logic component
may be programmed to perform validation of a protocol for
communicating with such an external system, such as an external
storage node.
[0512] In embodiments, programming of programmable logic
components, such as CPLDs and the like may be performed to
accommodate a range of data sensing, collection and configuration
differences. In embodiments, reprogramming may be performed on one
or more components when adding and/or removing sensors, when
changing sensor types, when changing sensor configurations or
settings, when changing data storage configurations, when embedding
data collection template(s) into device programs, when adding
and/or removing data collection modules (e.g., scaling a system),
when a lower cost device is used that may limit functionality or
resources over a higher cost device, and the like. A programmable
logic component may be programmed to propagate programs for other
programmable components via a dedicated programmable logic device
programming channel, via a daisy chain programming architecture,
via a mesh of programmable logic components, via a hub-and-spoke
architecture of interconnected components, via a ring configuration
(e.g., using a communication token, and the like).
[0513] In embodiments, a system for data collection in an
industrial environment comprising distributed programmable logic
devices connected by a dedicated control bus may be deployed with
drilling machines in an oil and gas harvesting environment, such as
an oil and/or gas field. A drilling machine has many active
portions that may be operated, monitored, and adjusted during a
drilling operation. Sensors to monitor a crown block may be
physically isolated from sensors for monitoring a blowout preventer
and the like. To effectively maintain control of this wide range
and diverse disposition of sensors, programmable logic components,
such as Complex Programmable Logic Devices ("CPLD") may be
distributed throughout the drilling machine. While each CPLD may be
configured with a program to facilitate operation of a limited set
of sensors, at least portions of the CPLD may be connected by a
dedicated bus for facilitating coordination of sensor control,
operation and use. In an example, a set of sensors may be disposed
proximal to a mud pump or the like to monitor flow, density, mud
tank levels, and the like. One or more CPLD may be deployed with
each sensor (or a group of sensors) to operate the sensors and
sensor signal routing and collection resources. The CPLD in this
mud pump group may be interconnected by a dedicated control bus to
facilitate coordination of sensor and data collection resource
control and the like. This dedicated bus may extend physically
and/or logically beyond the mud pump control portion of the drill
machine so that CPLD of other portions (e.g., the crown block and
the like) may coordinate data collection and related activity
through portions of the drilling machine.
[0514] In embodiments, a system for data collection in an
industrial environment comprising distributed programmable logic
devices connected by a dedicated control bus may be deployed with
compressors in an oil and gas harvesting environment, such as an
oil and/or gas field. Compressors are used in the oil and gas
industry for compressing a variety of gases and purposes include
flash gas, gas lift, reinjection, boosting, vapor-recovery, casing
head and the like. Collecting data from sensors for these different
compressor functions may require substantively different control
regimes. Distributing CPLDs programmed with different control
regimes is an approach that may accommodate these diverse data
collection requirements. One or more CPLDs may be disposed with
sets of sensors for the different compressor functions. A dedicated
control bus may be used to facilitate coordination of control
and/or programming of CPLDs in and across compressor instances. In
an example, a CPLD may be configured to manage a data collection
infrastructure for sensors disposed to collect compressor-related
conditions for flash gas compression; a second CPLD or group of
CPLDs may be configured to manage a data collection infrastructure
for sensors disposed to collect compressor related conditions for
vapor-recovery gas compression. These groups of CPLDs may operate
control programs.
[0515] In embodiments, a system for data collection in an
industrial environment comprising distributed programmable logic
devices connected by a dedicated control bus may be deployed in a
refinery with turbines for oil and gas production, such as with
modular impulse steam turbines. A system for collection of data
from impulse steam turbines may be configured with a plurality of
condition sensing and collection modules adapted for specific
functions of an impulse steam turbine. Distributing CPLDs along
with these modules can facilitate adaptable data collection to suit
individual installations. As an example, blade conditions, such as
tip rotational rate, temperature rise of the blades, impulse
pressure, blade acceleration rate, and the like may be captured in
data collection modules configured with sensors for sensing these
conditions. Other modules may be configured to collect data
associated with valves (e.g., in a multi-valve configuration, one
or more modules may be configured for each valve or for a set of
valves), turbine exhaust (e.g., radial exhaust data collection may
be configured differently than axial exhaust data collection),
turbine speed sensing may be configured differently for fixed
versus variable speed implementations, and the like. Additionally,
impulse gas turbine systems may be installed with other systems,
such as combined cycle systems, cogeneration systems, solar power
generation systems, wind power generation systems, hydropower
generation systems, and the like. Data collection requirements for
these installations may also vary. Using a CPLD-based, modular data
collection system that uses a dedicated interconnection bus for the
CPLDs may facilitate programming and/or reprogramming of each
module directly in place without having to shut down or physically
access each module.
[0516] Referring to FIG. 45, an exemplary embodiment of a system
for data collection in an industrial environment comprising
distributed CPLDs interconnected by a bus for control and/or
programming thereof is depicted. An exemplary data collection
module 7200 may comprise one or more CPLDs 7206 for controlling one
or more data collection system resources, such as sensors 7202 and
the like. Other data collection resources that a CPLD may control
may include crosspoint switches, multiplexers, data converters, and
the like. CPLDs on a module may be interconnected by a bus, such as
a dedicated logic bus 7204 that may extend beyond a data collection
module to CPLDs on other data collection modules. Data collection
modules, such as module 7200 may be configured in the environment,
such as on an industrial machine 7208 (e.g., an impulse gas
turbine) and/or 7210 (e.g., a co-generation system), and the like.
Control and/or configuration of the CPLDs may be handled by a
controller 7212 in the environment. Data collection and routing
resources and interconnection (not shown) may also be configured
within and among data collection modules 7200 as well as between
and among industrial machines 7208 and 7210, and/or with external
systems, such as Internet portals, data analysis servers, and the
like to facilitate data collection, routing, storage, analysis, and
the like.
[0517] An example system for data collection in an industrial
environment includes a number of industrial condition sensing and
acquisition modules, with a programmable logic component disposed
on each of the modules, where the programmable logic component
controls a portion of the sensing and acquisition functional of the
corresponding module. The system includes communication bus that is
dedicated to interconnecting the at least one programmable logic
component disposed on at least one of the plurality of modules,
wherein the communication bus extends to other programmable logic
components on other sensing and acquisition modules.
[0518] In certain further embodiments, a system includes the
programmable logic component programmed via the communication bus,
the communication bus including a portion dedicated to programming
of the programmable logic components, controlling a portion of the
sensing and acquisition functionality of a module by a power
control function such as: controlling power of a sensor, a
multiplexer, a portion of the module, and/or controlling a sleep
mode of the programmable logic component; controlling a portion of
the sensing and acquisition functionality of a module by providing
a voltage reference to a sensor and/or an analog-to-digital
converter disposed on the module, by detecting a relative the phase
of at least two analog signals derived from at least two sensors
disposed on the module; by controlling sampling of data provided by
at least one sensor disposed on the module; by detecting a peak
voltage of a signal provided by a sensor disposed on the module;
and/or by configuring at least one multiplexer disposed on the
module by specifying to the multiplexer a mapping of at least one
input and one output. In certain embodiments, the communication bus
extends to other programmable logic components on other condition
sensing and/or acquisition modules. In certain embodiments, a
module may be an industrial environment condition sensing module.
In certain embodiments, a module control program includes an
algorithm for implementing an intelligent sensor interface
communication protocol, such as an IEEE1451.2 compatible
intelligent sensor interface communication protocol. In certain
embodiments, a programmable logic component includes configuring
the programmable logic component and/or the sensing or acquisition
module to implement a smart band data collection template. Example
and non-limiting programmable logic components include field
programmable gate arrays, complex programmable logic devices,
and/or microcontrollers.
[0519] An example system includes a drilling machine for oil and
gas field use, with a condition sensing and/or acquisition module
to monitor aspects of a drilling machine. Without limitation, a
further example system includes monitoring a compressor and/or
monitoring an impulse steam engine.
[0520] In embodiments, a system for data collection in an
industrial environment may include a trigger signal and at least
one data signal that share a common output of a signal multiplexer
and upon detection of a condition in the industrial environment,
such as a state of the trigger signal, the common output is
switched to propagate either the data signal or the trigger signal.
Sharing an output between a data signal and a trigger signal may
also facilitate reducing a number of individually routed signals in
an industrial environment. Benefits of reducing individually routed
signals may include reducing the number of interconnections between
data collection module, thereby reducing the complexity of the
industrial environment. Trade-offs for reducing individually routed
signals may include increasing sophistication of logic at signal
switching modules to implement the detection and conditional
switching of signals A net benefit of this added localized logic
complexity may be an overall reduction in the implementation
complexity of such a data collection system in an industrial
environment.
[0521] Exemplary deployment environments may include environments
with trigger signal channel limitations, such as existing data
collection systems that do not have separate trigger support for
transporting an additional trigger signal to a module with
sufficient computing sophistication to perform trigger detection.
Another exemplary deployment may include systems that require at
least some autonomous control for performing data collection.
[0522] In embodiments, a system for data collection in an
industrial environment may include an analog switch that switches
between a first input, such as a trigger input and a second input,
such as a data input based on a condition of the first input. A
trigger input may be monitored by a portion of the analog switch to
detect a change in the signal, such as from a lower voltage to a
higher voltage relative to a reference or trigger threshold
voltage. In embodiments, a device that may receive the switched
signal from the analog switch may monitor the trigger signal for a
condition that indicates a condition for switching from the trigger
input to the data input. When a condition of the trigger input is
detected, the analog switch may be reconfigured, to direct the data
input to the same output that was propagating the trigger
output.
[0523] In embodiments, a system for data collection in an
industrial environment may include an analog switch that directs a
first input to an output of the analog switch until such time as
the output of the analog switch indicates that a second input
should be directed to the output of the analog switch. The output
of the analog switch may propagate a trigger signal to the output.
In response to the trigger signal propagating through the switch
transitioning from a first condition (e.g., a first voltage below a
trigger threshold voltage value) to a second condition (e.g., a
second voltage above the trigger threshold voltage value), the
switch may stop propagating the trigger signal and instead
propagate another input signal to the output. In embodiments, the
trigger signal and the other data signal may be related, such as
the trigger signal may indicate a presence of an object being
placed on a conveyer and the data signal represents a strain placed
on the conveyer.
[0524] In embodiments, to facilitate timely detection of the
trigger condition, a rate of sampling of the output of the analog
switch may be adjustable, so that, for example, the rate of
sampling is higher while the trigger signal is propagated and lower
when the data signal is propagated. Alternatively, a rate of
sampling may be fixed for either the trigger or the data signal. In
embodiments, the rate of sampling may be based on a predefined time
from trigger occurrence to trigger detection and may be faster than
a minimum sample rate to capture the data signal.
[0525] In embodiments, routing a plurality of hierarchically
organized triggers onto another analog channel may facilitate
implementing a hierarchical data collection triggering structure in
an industrial environment. A data collection template to implement
a hierarchical trigger signal architecture may include signal
switch configuration and function data that may facilitate a signal
switch facility, such as an analog crosspoint switch or multiplexer
to output a first input trigger in a hierarchy, and based on the
first trigger condition being detected, output a second input
trigger in the hierarchy on the same output as the first input
trigger by changing an internal mapping of inputs to outputs. Upon
detection of the second input trigger condition, the output may be
switched to a data signal, such as data from a sensor in an
industrial environment.
[0526] In embodiments, upon detection of a trigger condition, in
addition to switching from the trigger signal to a data signal, an
alarm may be generated and optionally propagated to a higher
functioning device/module. In addition to switching to a data
signal, upon detection of a state of the trigger, sensors that
otherwise may be disabled or powered down may be
energized/activated to begin to produce data for the newly selected
data signal. Activating might alternatively include sending a reset
or refresh signal to the sensor(s).
[0527] In embodiments, a system for data collection in an
industrial environment may include a system for routing a trigger
signal onto a data signal path in association with a gearbox of an
industrial vehicle. Combining a trigger signal onto a signal path
that is also used for a data signal may be useful in gearbox
applications by reducing the number of signal lines that need to be
routed, while enabling advanced functions, such as data collection
based on pressure changes in the hydraulic fluid and the like. As
an example, a sensor may be configured to detect a pressure
difference in the hydraulic fluid that exceeds a certain threshold
as may occur when the hydraulic fluid flow is directed back into
the impeller to give higher torque at low speeds. The output of
such a sensor may be configured as a trigger for collecting data
about the gearbox when operating at low speeds. In an example, a
data collection system for an industrial environment may have a
multiplexer or switch that facilitates routing either a trigger or
a data channel over a single signal path. Detecting the trigger
signal from the pressure sensor may result in a different signal
being routed through the same line that the trigger signal was
routed by switching a set of controls. A multiplexer may, for
example, output the trigger signal until the trigger signal is
detected as indicating that the output should be changed to the
data signal. As a result of detecting the high-pressure condition,
a data collection activity may be activated so that data can be
collected using the same line that was recently used by the trigger
signal.
[0528] In embodiments, a system for data collection in an
industrial environment may include a system for routing a trigger
signal onto a data signal path in association with a vehicle
suspension for truck and car operation. Vehicle suspension,
particularly active suspension may include sensors for detecting
road events, suspension conditions, and vehicle data, such as
speed, steering, and the like. These conditions may not always need
to be detected, except, for example, upon detection of a trigger
condition. Therefore, combining the trigger condition signal and at
least one data signal on a single physical signal routing path
could be implemented. Doing so may reduce costs due to fewer
physical connections required in such a data collection system. In
an example, a sensor may be configured to detect a condition, such
as a pot hole, to which the suspension must react. Data from the
suspension may be routed along the same signal routing path as this
road condition trigger signal so that upon detection of the pot
hole, data may be collected that may facilitate determining aspects
of the suspension's reaction to the pot hole.
[0529] In embodiments, a system for data collection in an
industrial environment may include a system for routing a trigger
signal onto a data signal path in association with a turbine for
power generation in a power station. A turbine used for power
generation may be retrofitted with a data collection system that
optimizes existing data signal lines to implement greater data
collection functions. One such approach involves routing new
sources of data over existing lines. While multiplexing signals
generally satisfies this need, combining a trigger signal with a
data signal via a multiplexer or the like can further improve data
collection. In an example, a first sensor may include a thermal
threshold sensor that may measure the temperature of an aspect of a
power generation turbine. Upon detection of that trigger (e.g., by
the temperature rising above the thermal threshold), a data
collection system controller may send a different data collection
signal over the same line that was used to detect the trigger
condition. This may be accomplished by a controller or the like
sensing the trigger signal change condition and then signaling to
the multiplexer to switch from the trigger signal to a data signal
to be output on the same line as the trigger signal for data
collection. In this example, when a turbine is detected as having a
portion that exceeds its safe thermal threshold, a secondary safety
signal may be routed over the trigger signal path and monitored for
additional safety conditions, such as overheating and the like.
[0530] Referring to FIG. 46, an embodiment of routing a trigger
signal over a data signal path in a data collection system in an
industrial environment is depicted. Signal multiplexer 7400 may
receive a trigger signal on a first input from a sensor or other
trigger source 7404 and a data signal on a second input from a
sensor for detecting a temperature associated with an industrial
machine in the environment 7402. The multiplexer 7400 may be
configured to output the trigger signal onto an output signal path
7406. A data collection module 7410 may process the signal on the
data path 7406 looking for a change in the signal indicative of a
trigger condition provided from the trigger sensor 7404 through the
multiplexer 7400. Upon detection, a control output 7408 may be
changed and thereby control the multiplexer 7400 to start
outputting data from the temperature probe 7402 by switching an
internal switch or the like that may control one or more of the
inputs that may be routed to the output 7406. Data collection
facility 7410 may activate a data collection template in response
to the detected trigger that may include switching the multiplexer
and collecting data into triggered data storage 7412. Upon
completion of the data collection activity, multiplexer control
signal 7408 may revert to its initial condition so that trigger
sensor 7404 may be monitored again.
[0531] An example system for data collection in an industrial
environment includes an analog switch that directs a first input to
an output of the analog switch until such time as the output of the
analog switch indicates that a second input should be directed to
the output of the analog switch. In certain further embodiments,
the example system includes: where the output of the analog switch
indicated that the second input should be directed to the output
based on the output transitioning from a pending condition to a
triggered condition; wherein the triggered condition includes
detecting the output presenting a voltage above a trigger voltage
value; routing a number of signals with the analog switch from
inputs on the analog switch to outputs on the analog switch in
response to the output of the analog switch indicating that the
second input should be directed to the output; sampling the output
of the analog switch at a rate that exceeds a rate of transition
for a number of signals input to the analog switch; and/or
generating an alarm signal when the output of the analog switch
indicates that a second input should be directed to the output of
the analog switch.
[0532] An example system for data collection in an industrial
environment includes an analog switch that switches between a first
input and a second input based on a condition of the first input.
In certain further embodiments, the condition of the first input
comprises the first input presenting a triggered condition, and/or
the triggered condition includes detecting the first input
presenting a voltage above a trigger voltage value. In certain
embodiments, the analog switch includes routing a plurality of
signals with the analog from inputs on the analog switch to outputs
on the analog switch based on the condition of the first input,
sampling an input of the analog switch at a rate that exceeds a
rate of transition for a plurality of signals input to the analog
switch, and/or generating an alarm signal based on the condition of
the first input.
[0533] An example system for data collection in an industrial
environment includes a trigger signal and at least one data signal
that share a common output of a signal multiplexer, and upon
detection of a predefined state of the trigger signal, the common
output is configured to propagate the at least one data signal
through the signal multiplexer. In certain further embodiments, the
signal multiplexer is an analog multiplexer, the predefined state
of the trigger signal is detected on the common output, detection
of the predefined state of the trigger signal includes detecting
the common output presenting a voltage above a trigger voltage
value, the multiplexer includes routing a plurality of signals with
the multiplexer from inputs on the multiplexer to outputs on the
multiplexer in response to detection of the predefined state of the
trigger signal, the multiplexer includes sampling the output of the
multiplexer at a rate that exceeds a rate of transition for a
plurality of signals input to the multiplexer, the multiplexer
includes generating an alarm in response to detection of the
predefined state of the trigger signal, and/or the multiplexer
includes activating at least one sensor to produce the at least one
data signal. Without limitation, example systems include:
monitoring a gearbox of an industrial vehicle by directing a
trigger signal representing a condition of the gearbox to an output
of the analog switch until such time as the output of the analog
switch indicates that a second input representing a condition of
the gearbox related to the trigger signal should be directed to the
output of the analog switch; monitoring a suspension system of an
industrial vehicle by directing a trigger signal representing a
condition of the suspension to an output of the analog switch until
such time as the output of the analog switch indicates that a
second input representing a condition of the suspension related to
the trigger signal should be directed to the output of the analog
switch; and/or monitoring a power generation turbine by directing a
trigger signal representing a condition of the power generation
turbine to an output of the analog switch until such time as the
output of the analog switch indicates that a second input
representing a condition of the power generation turbine related to
the trigger signal should be directed to the output of the analog
switch.
[0534] In embodiments, a system for data collection in an
industrial environment may include a data collection system that
monitors at least one signal for a set of collection band
parameters and upon detection of a parameter from the set of
collection band parameters in the signal, configures collection of
data from a set of sensors based on the detected parameter. The set
of selected sensors, the signal, and the set of collection band
parameters may be part of a smart bands data collection template
that may be used by the system when collecting data in an
industrial environment. A motivation for preparing a smart-bands
data collection template may include monitoring a set of conditions
of an industrial machine to facilitate improved operation, reduce
down time, preventive maintenance, failure prevention, and the
like. Based on analysis of data about the industrial machine, such
as those conditions that may be detected by the set of sensors, an
action may be taken, such as notifying a user of a change in the
condition, adjusting operating parameters, scheduling preventive
maintenance, triggering data collection from additional sets of
sensors, and the like. An example of data that may indicate a need
for some action may include changes that may be detectable through
trends present in the data from the set of sensors. Another example
is trends of analysis values derived from the set of sensors.
[0535] In embodiments, the set of collection band parameters may
include values received from a sensor that is configured to sense a
condition of the industrial machine (e.g., bearing vibration).
However, a set of collection band parameters may instead be a trend
of data received from the sensor (e.g., a trend of bearing
vibration across a plurality of vibration measurements by a bearing
vibration sensor). In embodiments, a set of collection band
parameters may be a composite of data and/or trends of data from a
plurality of sensors (e.g., a trend of data from on-axis and
off-axis vibration sensors). In embodiments, when a data value
derived from one or more sensors as described herein is
sufficiently close to a value of data in the set of collection band
parameters, the data collection activity from the set of sensors
may be triggered. Alternatively, a data collection activity from
the set of sensors may be triggered when a data value derived from
the one or more sensors (e.g., trends and the like) falls outside
of a set of collection band parameters. In an example, a set of
data collection band parameters for a motor may be a range of
rotational speeds from 95% to 105% of a select operational
rotational speed. So long as a trend of rotational speed of the
motor stays within this range, a data collection activity may be
deferred. However, when the trend reaches or exceeds this range,
then a data collection activity, such as one defined by a smart
bands data collection template may be triggered.
[0536] In embodiments, triggering a data collection activity, such
as one defined by a smart bands data collection template, may
result in a change to a data collection system for an industrial
environment that may impact aspects of the system such as data
sensing, switching, routing, storage allocation, storage
configuration, and the like. This change to the data collection
system may occur in near real time to the detection of the
condition; however, it may be scheduled to occur in the future. It
may also be coordinated with other data collection activities so
that active data collection activities, such as a data collection
activity for a different smart bands data collection template, can
complete prior to the system being reconfigured to meet the smart
bands data collection template that is triggered by the sensed
condition meeting the smart bands data collection trigger.
[0537] In embodiments, processing of data from sensors may be
cumulative over time, over a set of sensors, across machines in an
industrial environment, and the like. While a sensed value of a
condition may be sufficient to trigger a smart bands data
collection template activity, data may need to be collected and
processed over time from a plurality of sensors to generate a data
value that may be compared to a set of data collection band
parameters for conditionally triggering the data collection
activity. Using data from multiple sensors and/or processing data,
such as to generate a trend of data values and the like may
facilitate preventing inconsequential instances of a sensed data
value being outside of an acceptable range from causing unwarranted
smart bands data collection activity. In an example, if a vibration
from a bearing is detected outside of an acceptable range
infrequently, then trending for this value over time may be useful
to detect if the frequency is increasing, decreasing, or staying
substantially constant or within a range of values. If the
frequency of such a value is found to be increasing, then such a
trend is indicative of changes occurring in operation of the
industrial machine as experienced by the bearing. An acceptable
range of values of this trended vibration value may be established
as a set of data collection band parameters against which vibration
data for the bearing will be monitored. When the trended vibration
value is outside of this range of acceptable values, a smart bands
data collection activity may be activated.
[0538] In embodiments, a system for data collection in an
industrial environment that supports smart band data collection
templates may be configured with data processing capability at a
point of sensing of one or more conditions that may trigger a smart
bands data collection template data collection activity, such as:
by use of an intelligent sensor that may include data processing
capabilities; by use of a programmable logic component that
interfaces with a sensor and processes data from the sensor; by use
of a computer processor, such as a microprocessor and the like
disposed proximal to the sensor; and the like. In embodiments,
processing of data collected from one or more sensors for detecting
a smart bands template data collection activity may be performed by
remote processors, servers, and the like that may have access to
data from a plurality of sensors, sensor modules, industrial
machines, industrial environments, and the like.
[0539] In embodiments, a system for data collection in an
industrial environment may include a data collection system that
monitors an industrial environment for a set of parameters, and
upon detection of at least one parameter, configures the collection
of data from a set of sensors and causes a data storage controller
to adapt a configuration of data storage facilities to support
collection of data from the set of sensors based on the detected
parameter. The methods and systems described herein for
conditionally changing a configuration of a data collection system
in an industrial environment to implement a smart bands data
collection template may further include changes to data storage
architectures. As an example, a data storage facility may be
disposed on a data collection module that may include one or more
sensors for monitoring conditions in an industrial environment.
This local data storage facility may typically be configured for
rapid movement of sensed data from the module to a next level
sensing or processing module or server. When a smart bands data
collection condition is detected, sensor data from a plurality of
sensors may need to be captured concurrently. To accommodate this
concurrent collection, the local memory may be reconfigured to
capture data from each of the plurality of sensors in a coordinated
manner, such as repeatedly sampling each of the sensors
synchronously, or with a known offset, and the like, to build up a
set of sensed data that may be much larger than would typically be
captured and moved through the local memory. A storage control
facility for controlling the local storage may monitor the movement
of sensor data into and out of the local data storage, thereby
ensuring safe movement of data from the plurality of sensors to the
local data storage and on to a destination, such as a server,
networked storage facility, and the like. The local data storage
facility may be configured so that data from the set of sensors
associated with a smart bands data collection template are securely
stored and readily accessible as a set of smart band data to
facilitate processing the smart band-specific data. As an example,
local storage may comprise non-volatile memory (NVM). To prepare
for data collection in response to a smart band data collection
template being triggered, portions of the NVM may be erased to
prepare the NVM to receive data as indicated in the template.
[0540] In embodiments, multiple sensors may be arranged into a set
of sensors for condition-specific monitoring. Each set, which may
be a logical set of sensors, may be selected to provide information
about elements in an industrial environment that may provide
insight into potential problems, root causes of problems, and the
like. Each set may be associated with a condition that may be
monitored for compliance with an acceptable range of values. The
set of sensors may be based on a machine architecture, hierarchy of
components, or a hierarchy of data that contributes to a finding
about a machine that may usefully be applied to maintaining or
improving performance in the industrial environment. Smart band
sensor sets may be configured based on expert system analysis of
complex conditions, such as machine failures and the like. Smart
band sensor sets may be arranged to facilitate knowledge gathering
independent of a particular failure mode or history. Smart band
sensor sets may be arranged to test a suggested smart band data
collection template prior to implementing it as part of an
industrial machine operations program. Gathering and processing
data from sets of sensors may facilitate determining which sensors
contribute meaningful data to the set, and those sensors that do
not contribute can be removed from the set. Smart band sensor sets
may be adjusted based on external data, such as industry studies
that indicate the types of sensor data that is most helpful to
reduce failures in an industrial environment.
[0541] In embodiments, a system for data collection in an
industrial environment may include a data collection system that
monitors at least one signal for compliance to a set of collection
band conditions and upon detection of a lack of compliance,
configures the collection of data from a predetermined set of
sensors associated with the monitored signal. Upon detection of a
lack of compliance, a collection band template associated with the
monitored signal may be accessed, and resources identified in the
template may be configured to perform the data collection. In
embodiments, the template may identify sensors to activate, data
from the sensors to collect, duration of collection or quantity of
data to be collected, destination (e.g., memory structure) to store
the collected data, and the like. In embodiments, a smart band
method for data collection in an industrial environment may include
periodic collection of data from one or more sensors configured to
sense a condition of an industrial machine in the environment. The
collected data may be checked against a set of criteria that define
an acceptable range of the condition. Upon validation that the
collected data is either approaching one end of the acceptable
limit or is beyond the acceptable range of the condition, data
collection may commence from a smart-band group of sensors
associated with the sensed condition based on a smart-band
collection protocol configured as a data collection template. In
embodiments, an acceptable range of the condition is based on a
history of applied analytics of the condition. In embodiments, upon
validation of the acceptable range being exceeded, data storage
resources of a module in which the sensed condition is detected may
be configured to facilitate capturing data from the smart band
group of sensors.
[0542] In embodiments, monitoring a condition to trigger a smart
band data collection template data collection action may be: in
response to: a regulation, such as a safety regulation; in response
to an upcoming activity, such as a portion of the industrial
environment being shut down for preventive maintenance; in response
to sensor data missing from routine data collection activities; and
the like. In embodiments, in response to a faulty sensor or sensor
data missing from a smart band template data collection activity,
one or more alternate sensors may be temporarily included in the
set of sensors so as to provide data that may effectively
substitute for the missing data in data processing algorithms.
[0543] In embodiments, smart band data collection templates may be
configured for detecting and gathering data for smart band analysis
covering vibration spectra, such as vibration envelope and current
signature for spectral regions or peaks that may be combinations of
absolute frequency or factors of machine related parameters,
vibration time waveforms for time-domain derived calculations
including, without limitation: RMS overall, peak overall, true
peak, crest factor, and the like; vibration vectors, spectral
energy humps in various regions (e.g., low-frequency region, high
frequency region, low orders, and the like); pressure-volume
analysis and the like.
[0544] In embodiments, a system for data collection that applies
smart band data collection templates may be applied to an
industrial environment, such as ball screw actuators in an
automated production environment. Smart band analysis may be
applied to ball screw actuators in industrial environments such as
precision manufacturing or positioning applications (e.g.,
semiconductor photolithography machines, and the like). As a
typical primary objective of using a ball screw is for precise
positioning, detection of variation in the positioning mechanism
can help avoid costly defective production runs. Smart bands
triggering and data collection may help in such applications by
detecting, through smart band analysis, potential variations in the
positioning mechanism such as in the ball screw mechanism, a worm
drive, a linear motor, and the like. In an example, data related to
a ball screw positioning system may be collected with a system for
data collection in an industrial environment as described herein. A
plurality of sensors may be configured to collect data such as
screw torque, screw direction, screw speed, screw step, screw home
detection, and the like. Some portion of this data may be processed
by a smart bands data analysis facility to determine if variances,
such as trends in screw speed as a function of torque, approach or
exceed an acceptable threshold. Upon such a determination, a data
collection template for the ball screw production system may be
activated to configure the data sensing, routing, and collection
resources of the data collection system to perform data collection
to facilitate further analysis. The smart band data collection
template facilitates rapid collection of data from other sensors
than screw speed and torque, such as position, direction,
acceleration, and the like by routing data from corresponding
sensors over one or more signal paths to a data collector. The
duration and order of collection of the data from these sources may
be specified in the smart bands data collection template so that
data required for further analysis is effectively captured.
[0545] In embodiments, a system for data collection that applies
smart band data collection templates to configure and utilize data
collection and routing infrastructure may be applied to ventilation
systems in mining environments. Ventilation provides a crucial role
in mining safety. Early detection of potential problems with
ventilation equipment can be aided by applying a smart bands
approach to data collection in such an environment. Sensors may be
disposed for collecting information about ventilation operation,
quality, and performance throughout a mining operation. At each
ventilation device, ventilation-related elements, such as fans,
motors, belts, filters, temperature gauges, voltage, current, air
quality, poison detection, and the like may be configured with a
corresponding sensor. While variation in any one element (e.g., air
volume per minute, and the like) may not be indicative of a
problem, smart band analysis may be applied to detect trends over
time that may be suggestive of potential problems with ventilation
equipment. To perform smart bands analysis, data from a plurality
of sensors may be required to form a basis for analysis. By
implementing data collection systems for ventilation stations, data
from a ventilation system may be captured. In an example, a smart
band analysis may be indicated for a ventilation station. In
response to this indication, a data collection system may be
configured to collect data by routing data from sensors disposed at
the ventilation station to a central monitoring facility that may
gather and analyze data from several ventilation stations.
[0546] In embodiments, a system for data collection that applies
smart band data collection templates to configure and utilize data
collection and routing infrastructure may be applied to drivetrain
data collection and analysis in mining environments. A drivetrain,
such as a drivetrain for a mining vehicle, may include a range of
elements that could benefit from use of the methods and systems of
data collection in an industrial environment as described herein.
In particular, smart band-based data collection may be used to
collect data from heavy duty mining vehicle drivetrains under
certain conditions that may be detectable by smart bands analysis.
A smart bands-based data collection template may be used by a
drivetrain data collection and routing system to configure sensors,
data paths, and data collection resources to perform data
collection under certain circumstances, such as those that may
indicate an unacceptable trend of drivetrain performance. A data
collection system for an industrial drivetrain may include sensing
aspects of a non-steering axle, a planetary steering axle,
driveshafts, (e.g., main and wing shafts), transmissions, (e.g.,
standard, torque converters, long drop), and the like. A range of
data related to these operational parts may be collected. However,
data for support and structural members that support the drivetrain
may also need to be collected for thorough smart band analysis.
Therefore, collection across this wide range of drivetrain-related
components may be triggered based on a smart band analysis
determination of a need for this data. In an example, a smart band
analysis may indicate potential slippage between a main and wing
driveshaft that may represented by an increasing trend in response
delay time of the wing drive shaft to main drive shaft operation.
In response to this increasing trend, data collection modules
disposed throughout the mining vehicle's drive train may be
configured to route data from local sensors to be collected and
analyzed by data collectors. Mining vehicle drivetrain smart based
data collection may include a range of templates based on which
type of trend is detected. If a trend related to a steering axle is
detected, a data collection template to be implemented may be
different in sensor content, duration, and the like than for a
trend related to power demand for a normalized payload. Each
template could configure data sensing, routing, and collection
resources throughout the vehicle drive train accordingly.
[0547] Referring to FIG. 47, a system for data collection in an
industrial environment that facilitates data collection for smart
band analysis is depicted. A system for data collection in an
industrial environment may include a smart band analysis data
collection template repository 7600 in which smart band templates
7610 for data collection system configuration and collection of
data may be stored and accessed by a data collection controller
7602. The templates 7610 may include data collection system
configuration 7604 and operation information 7606 that may identify
sensors, collectors, signal paths, and information for initiation
and coordination of collection, and the like. A controller 7602 may
receive an indication, such as a command from a smart band analysis
facility 7608 to select and implement a specific smart band
template 7610. The controller 7602 may access the template 7610 and
configure the data collection system resources based on the
information in that template. In embodiments, the template may
identify: specific sensors; a multiplexer/switch configuration,
data collection trigger/initiation signals and/or conditions, time
duration and/or amount of data for collection; destination of
collected data; intermediate processing, if any; and any other
useful information, (e.g., instance identifier, and the like). The
controller 7602 may configure and operate the data collection
system to perform the collection for the smart band template and
optionally return the system configuration to a previous
configuration.
[0548] An example system for data collection in an industrial
environment includes a data collection system that monitors at
least one signal for a set of collection band parameters and, upon
detection of a parameter from the set of collection band
parameters, configures portions of the system and performs
collection of data from a set of sensors based on the detected
parameter. In certain further embodiments, the signal includes an
output of a sensor that senses a condition in the industrial
environment, where the set of collection band parameters comprises
values derivable from the signal that are beyond an acceptable
range of values derivable from the signal; where the at least one
signal includes an output of a sensor that senses a condition in
the industrial environment; wherein configuring portions of the
system includes configuring a storage facility to accept data
collected from the set of sensors; where configuring portions of
the system includes configuring a data routing portion includes at
least one of: an analog crosspoint switch, a hierarchical
multiplexer, an analog-to-digital converter, an intelligent sensor,
and/or a programmable logic component; wherein detection of a
parameter from the set of collection band parameters comprises
detecting a trend value for the signal being beyond an acceptable
range of trend values; and/or where configuring portions of the
system includes implementing a smart band data collection template
associated with the detected parameter. In certain embodiments, a
data collection system monitors a signal for data values within a
set of acceptable data values that represent acceptable collection
band conditions for the signal and, upon detection of a data value
for the at least one signal outside of the set of acceptable data
values, triggers a data collection activity that causes collecting
data from a predetermined set of sensors associated with the
monitored signal. In certain further embodiment, a data collection
system includes the signal including an output of a sensor that
senses a condition in the industrial environment; where the set of
acceptable data value includes values derivable from the signal
that are within an acceptable range of values derivable from the
signal; configuring a storage facility of the system to facilitate
collecting data from the predetermined set of sensors in response
to the detection of a data value outside of the set of acceptable
data values; configuring a data routing portion of the system
including an analog crosspoint switch, a hierarchical multiplexer,
an analog-to-digital converter, an intelligent sensor, and/or a
programmable logic component in response to detecting a data value
outside of the set of acceptable data values; where detection of a
data value for the signal outside of the set of acceptable data
values includes detecting a trend value for the signal being beyond
an acceptable range of trend values; and/or where the data
collection activity is defined by a smart band data collection
template associated with the detected parameter.
[0549] An example method for data collection in an industrial
environment comprising includes an operation to collect data from
sensor(s) configured to sense a condition of an industrial machine
in the environment; an operation to check the collected data
against a set of criteria that define an acceptable range of the
condition; and in response to the collected data violating the
acceptable range of the condition, an operation to collect data
from a smart-band group of sensors associated with the sensed
condition based on a smart-band collection protocol configured as a
smart band data collection template. In certain further
embodiments, a method includes where violating the acceptable range
of the condition includes a trend of the data from the sensor(s)
approaching a maximum value of the acceptable range; where the
smart-band group of sensors is defined by the smart band data
collection template; where the smart band data collection template
includes a list of sensors to activate, data from the sensors to
collect, duration of collection of data from the sensors, and/or a
destination location for storing the collected data; where
collecting data from a smart-band group of sensors includes
configuring at least one data routing resource of the industrial
environment that facilitates routing data from the smart band group
of sensors to a plurality of data collectors; and/or where the set
of criteria includes a range of trend values derived by processing
the data from sensor(s).
[0550] Without limitation, an example system monitors a ball screw
actuator in an automated production environment, and monitors at
least one signal from the ball screw actuator for a set of
collection band parameters and, upon detection of a parameter from
the set of collection band parameters, configures portions of the
system and performs collection of data from a set of sensors
disposed to monitor conditions of the ball screw actuator based on
the detected parameter; another example system monitors a
ventilation system in a mining environment, and monitors at least
one signal from the ventilation system for a set of collection band
parameters and, upon detection of a parameter from the set of
collection band parameters, configures portions of the system and
performs collection of data from a set of sensors disposed to
monitor conditions of the ventilation system based on the detected
parameter; an example system monitors a drivetrain of a mining
vehicle, and monitors at least one signal from the drive train for
a set of collection band parameters and, upon detection of a
parameter from the set of collection band parameters, configures
portions of the system and performs collection of data from a set
of sensors disposed to monitor conditions of the drivetrain based
on the detected parameter.
[0551] In embodiments, a system for data collection in an
industrial environment may automatically configure local and remote
data collection resources and may perform data collection from a
plurality of system sensors that are identified as part of a group
of sensors that produce data that is required to perform
operational deflection shape rendering. In embodiments, the system
sensors are distributed throughout structural portions of an
industrial machine in the industrial environment. In embodiments,
the system sensors sense a range of system conditions including
vibration, rotation, balance, friction, and the like. In
embodiments, automatically configuring is in response to a
condition in the environment being detected outside of an
acceptable range of condition values. In embodiments, a sensor in
the identified group of system sensors senses the condition.
[0552] In embodiments, a system for data collection in an
industrial environment may configure a data collection plan, such
as a template, to collect data from a plurality of system sensors
distributed throughout a machine to facilitate automatically
producing an operational deflection shape visualization ("ODSV")
based on machine structural information and a data set used to
produce an ODSV of the machine.
[0553] In embodiments, a system for data collection in an
industrial environment may configure a data collection template for
collecting data in an industrial environment by identifying sensors
disposed for sensing conditions of preselected structural members
of an industrial machine in the environment based on an ODSV of the
industrial machine. In embodiments, the template may include an
order and timing of data collection from the identified
sensors.
[0554] In embodiments, methods and systems for data collection in
an industrial environment may include a method of establishing an
acceptable range of sensor values for a plurality of industrial
machine condition sensors by validating an operational deflection
shape visualization of structural elements of the machine as
exhibiting deflection within an acceptable range, wherein data from
the plurality of sensors used in the validated ODSV define the
acceptable range of sensor values.
[0555] In embodiments, a system for data collection in an
industrial environment may include a plurality of data sources,
such as sensors, that may be grouped for coordinated data
collection to provide data required to produce an ODSV. Information
regarding the sensors to group, data collection coordination
requirements, and the like may be retrieved from an ODSV data
collection template. Coordinated data collection may include
concurrent data collection. To facilitate concurrent data
collection from a portion of the group of sensors, sensor routing
resources of the system for data collection may be configured, such
as by configuring a data multiplexer to route data from the portion
of the group of sensors to which it connects to data collectors. In
embodiments, each such source that connects an input of the
multiplexer may be routed within the multiplexer to separate
outputs so that data from all of the connected sources may be
routed on to data collection elements of the industrial
environment. In embodiments, the multiplexer may include data
storage capabilities that may facilitate sharing a common output
for at least a portion of the inputs. In embodiments, a multiplexer
may include data storage capabilities and data bus-enabled outputs
so that data for each source may be captured in a memory and
transmitted over a data bus, such as a data bus that is common to
the outputs of the multiplexer. In embodiments, sensors may be
smart sensors that may include data storage capabilities and may
send data from the data storage to the multiplexer in a coordinated
manner that supports use of a common output of the multiplexer
and/or use of a common data bus.
[0556] In embodiments, a system for data collection in an
industrial environment may comprise templates for configuring the
data collection system to collect data from a plurality of sensors
to perform ODSV for a plurality of deflection shapes. Individual
templates may be configured for visualization of looseness, soft
joints, bending, twisting, and the like. Individual deflection
shape data collection templates may be configured for different
portions of a machine in an industrial environment.
[0557] In embodiments, a system for data collection in an
industrial environment may facilitate operational deflection shape
visualization that may include visualization of locations of
sensors that contributed data to the visualization. In the
visualization, each sensor that contributed data to generate the
visualization may be indicated by a visual element. The visual
element may facilitate user access to information about the sensor,
such as location, type, representative data contributed, path of
data from the sensor to a data collector, a deflection shape
template identifier, a configuration of a switch or multiplexer
through which the data is routed, and the like. The visual element
may be determined by associating sensor identification information
received from a sensor with information, such as a sensor map, that
correlates sensor identification information with physical location
in the environment. The information may appear in the visualization
in response to the visual element representing the sensor being
selected, such as by a user positioning a cursor on the sensor
visual element.
[0558] In embodiments, ODSV may benefit from data satisfying a
phase relationship requirement. A data collection system in the
environment may be configured to facilitate collecting data that
complies with the phase relationship requirement. Alternatively,
the data collection system may be configured to collect data from a
plurality of sensors that contains data that satisfies the phase
relationship requirements but may also include data that does not.
A post processing operation that may access phase detection data
may select a subset of the collected data.
[0559] In embodiments, a system for data collection in an
industrial environment may include a multiplexer receiving data
from a plurality of sensors and multiplexing the received data for
delivery to a data collector. The data collector may process the
data to facilitate ODSV. ODSV may require data from several
different sensors, and may benefit from using a reference signal,
such as data from a sensor, when processing data from the different
sensors. The multiplexer may be configured to provide data from the
different sensors, such as by switching among its inputs over time
so that data from each sensor may be received by the data
collector. However, the multiplexer may include a plurality of
outputs so that at least a portion of the inputs may be routed to
least two of the plurality of outputs. Therefore, in embodiments, a
multiple output multiplexer may be configured to facilitate data
collection that may be suitable for ODSV by routing a reference
signal from one of its inputs (e.g., data from an accelerometer) to
one of its outputs and multiplexing data from a plurality of its
outputs onto one or more of its outputs while maintaining the
reference signal output routing. A data collector may collect the
data from the reference output and use that to align the
multiplexed data from the other sensors.
[0560] In embodiments, a system for data collection in an
industrial environment may facilitate ODSV through coordinated data
collection related to conveyors for mining applications. Mining
operations may rely on conveyor systems to move material, supplies,
and equipment into and out of a mine. Mining operations may
typically operate around the clock; therefore, conveyor downtime
may have a substantive impact on productivity and costs. Advanced
analysis of conveyor and related systems that focuses on secondary
affects that may be challenging to detect merely through point
observation may be more readily detected via ODSV. Capturing
operational data related to vibration, stresses, and the like can
facilitate ODSV. However, coordination of data capture provides
more reliable results. Therefore, a data collection system that may
have sensors dispersed throughout a conveyor system can be
configured to facilitate such coordinated data collection. In an
example, capture of data affecting structural components of a
conveyor, such as; landing points and the horizontal members that
connect them and support the conveyer between landing points;
conveyer segment handoff points; motor mounts; mounts of conveyer
rollers and the like may need to be coordinated with data related
to conveyor dynamic loading, drive systems, motors, gates, and the
like. A system for data collection in an industrial environment,
such as a mining environment may include data sensing and
collection modules placed throughout the conveyor at locations such
as segment handoff points, drive systems, and the like. Each module
may be configured by one or more controllers, such as programmable
logic controllers, that may be connected through a physical or
logical (e.g., wireless) communication bus that aids in performing
coordinated data collection. To facilitate coordination, a
reference signal, such as a trigger and the like, may be
communicated among the modules for use when collecting data. In
embodiments, data collection and storage may be performed at each
module so as to reduce the need for real-time transfer of sensed
data throughout the mining environment. Transfer of data from the
modules to an ODSV processing facility may be performed after
collection, or as communication bandwidth between the modules and
the processing facility allows. ODSV can provide insight into
conditions in the conveyer, such as deflection of structural
members that may, over time cause premature failure. Coordinated
data collection with a data collection system for use in an
industrial environment, such as mining, can enable ODSV that may
reduce operating costs by reducing downtime due to unexpected
component failure.
[0561] In embodiments, a system for data collection in an
industrial environment may facilitate operational deflection shape
visualization through coordinated data collection related to fans
for mining applications. Fans provide a crucial function in mining
operations of moving air throughout a mine to provide ventilation,
equipment cooling, combustion exhaust evacuation, and the like.
Ensuring reliable and often continuous operation of fans may be
critical for miner safety and cost-effective operations. Dozens or
hundreds of fans may be used in large mining operations. Fans, such
as fans for ventilation management may include circuit, booster,
and auxiliary types. High capacity auxiliary fans may operate at
high speeds, over 2500 RPMs. Performing ODSV may reveal important
reliability information about fans deployed in a mining
environment. Collecting the range of data needed for ODSV of mining
fans may be performed by a system for collecting data in industrial
environments as described herein. In embodiments, sensing elements,
such as intelligent sensing and data collection modules may be
deployed with fans and/or fan subsystems. These modules may
exchange collection control information (e.g., over a dedicated
control bus and the like) so that data collection may be
coordinated in time and phase to facilitate ODSV.
[0562] A large auxiliary fan for use in mining may be constructed
for transportability into and through the mine and therefore may
include a fan body, intake and outlet ports, dilution valves,
protection cage, electrical enclosure, wheels, access panels, and
other structural and/or operational elements. The ODSV of such an
auxiliary fan may require collection of data from many different
elements. A system for data collection may be configured to sense
and collect data that may be combined with structural engineering
data to facilitate ODSV for this type of industrial fan.
[0563] Referring to FIG. 48, an embodiment of a system for data
collection in an industrial environment that performs coordinated
data collection suitable for ODSV is depicted. A system for data
collection in an industrial environment may include a ODSV data
collection template repository 7800 in which ODSV templates 7810
for data collection system configuration and collection of data may
be stored and accessed by a system for data collection controller
7802. The templates 7810 may include data collection system
configuration 7804 and operation information 7806 that may identify
sensors, collectors, signal paths, reference signal information,
information for initiation and coordination of collection, and the
like. A controller 7802 may receive an indication, such as a
command from a ODSV analysis facility 7808 to select and implement
a specific ODSV template 7810. The controller 7802 may access the
template 7810 and configure the data collection system resources
based on the information in that template. In embodiments, the
template may identify specific sensors, multiplexer/switch
configuration, reference signals for coordinating data collection,
data collection trigger/initiation signals and/or conditions, time
duration, and/or amount of data for collection, destination of
collected data, intermediate processing, if any, and any other
useful information (e.g., instance identifier, and the like). The
controller 7802 may configure and operate the data collection
system to perform the collection for the ODSV template and
optionally return the system configuration to a previous
configuration.
[0564] An example method of data collection for performing ODSV in
an industrial environment includes automatically configuring local
and remote data collection resources and collecting data from a
number of sensors using the configured resources, where the number
of sensors include a group of sensors that produce data that is
required to perform the ODSV. In certain further embodiments, an
example method further includes where the sensors are distributed
throughout structural portions of an industrial machine in the
industrial environment; where the sensors sense a range of system
conditions including vibration, rotation, balance, and/or friction;
where the automatically configuring is in response to a condition
in the environment being detected outside of an acceptable range of
condition values; where the condition is sensed by a sensor in a
group of system sensors; where automatically configuring includes
configuring a signal switching resource to concurrently connect a
portion of the group of sensors to data collection resources;
and/or where the signal switching resource is configured to
maintain a connection between a reference sensor and the data
collection resources throughout a period of collecting data from
the sensors to perform ODSV.
[0565] An example method of data collection in an industrial
environment includes configuring a data collection plan to collect
data from a number of system sensors distributed throughout a
machine in the industrial environment, the plan based on machine
structural information and an indication of data needed to produce
an ODSV of the machine; configuring data sensing, routing and
collection resources in the environment based on the data
collection plan; and collecting data based on the data collection
plan. In certain further embodiments, an example method further
includes: producing the ODSV; where the configuring data sensing,
routing, and collection resources is in response to a condition in
the environment being detected outside of an acceptable range of
condition values; where the condition is sensed by a sensor
identified in the data collection plan; where configuring resources
includes configuring a signal switching resource to concurrently
connect the plurality of system sensors to data collection
resources; and/or where the signal switching resource is configured
to maintain a connection between a reference sensor and the data
collection resources throughout a period of collecting data from
the sensors to perform ODSV.
[0566] An example system for data collection in an industrial
environment includes: a number of sensors disposed throughout the
environment; multiplexer that connects signals from the plurality
of sensors to data collection resources; and a processor for
processing data collected from the number of sensors in response to
the data collection template, where the processing results in an
ODSV of a portion of a machine disposed in the environment. In
certain further embodiments, an example system includes: where the
ODSV collection template further identifies a condition in the
environment on which performing data collection from the identified
sensors is dependent; where the condition is sensed by a sensor
identified in the ODSV data collection template; where the data
collection template specified inputs of the multiplexer to
concurrently connect to data collection resources; where the
multiplexer is configured to maintain a connection between a
reference sensor and the data collection resources throughout a
period of collecting data from the sensors to perform ODSV; where
the ODSV data collection template specifies data collection
requirements for performing ODSV for looseness, soft joints,
bending, and/or twisting of a portion of a machine in the
industrial environment; and/or where the ODSV collection template
specifies an order and timing of data collection from a plurality
of identified sensors.
[0567] An example method of monitoring a mining conveyer for
performing ODSV of the conveyer includes automatically configuring
local and remote data collection resources and collecting data from
a number of sensors disposed to sense the mining conveyor using the
configured resources, wherein the plurality of sensors comprise a
group of sensors that produce data that is required to perform the
operational deflection shape visualization of a portion of the
conveyor. An example method of monitoring a mining fan for
performing ODSV of the fan includes automatically configuring local
and remote data collection resources collecting data from a number
of sensors disposed to sense the fan using the configured
resources, and where the number of sensors include a group of
sensors that produce data that is sufficient or required to perform
ODSV of a portion of the fan.
[0568] In embodiments, a system for data collection in an
industrial environment may include a hierarchical multiplexer that
facilitates successive multiplexing of input data channels
according to a configurable hierarchy, such as a user configurable
hierarchy. The system for data collection in an industrial
environment may include the hierarchical multiplexer that
facilitates successive multiplexing of a plurality of input data
channels according to a configurable hierarchy. The hierarchy may
be automatically configured by a controller based on an operational
parameter in the industrial environment, such as a parameter of a
machine in the industrial environment.
[0569] In embodiments, a system for data collection in an
industrial environment may include a plurality of sensors that may
output data at different rates. The system may also include a
multiplexer module that receives sensor outputs from a first
portion of the plurality of sensors with similar output rates into
separate inputs of a first hierarchical multiplexer of the
multiplexer module. The first hierarchical multiplexer of the
multiplexer module may provide at least one multiplexed output of a
portion of its inputs to a second hierarchical multiplexer that
receives sensor outputs from a second portion of the plurality of
sensors with similar output rates and that provides at least one
multiplexed output of a portion of its inputs. In embodiments, the
output rates of the first set of sensors may be slower than the
output rates of the second set of sensors. In embodiments, data
collection rate requirements of the first set of sensors may be
lower than the data collection rate requirements of the second set
of sensors. In embodiments, the first hierarchical multiplexer
output is a time-multiplexed combination of a portion of its
inputs. In embodiments, the second hierarchical multiplexer
receives sensor signals with output rates that are similar to a
rate of output of the first multiplexer, wherein the first
multiplexer produces time-based multiplexing of the portion of its
plurality of inputs.
[0570] In embodiments, a system for data collection in an
industrial environment may include a hierarchical multiplexer that
is dynamically configured based on a data acquisition template. The
hierarchical multiplexer may include a plurality of inputs and a
plurality of outputs, wherein any input can be directed to any
output in response to sensor output collection requirements of the
template, and wherein a subset of the inputs can be multiplexed at
a first switching rate and output to at least one of the plurality
of outputs.
[0571] In embodiments, a system for data collection in an
industrial environment may include a plurality of sensors for
sensing conditions of a machine in the environment, a hierarchical
multiplexer, a plurality of analog-to-digital converters (ADCs), a
processor, local storage, and an external interface. The system may
use the processor to access a data acquisition template of
parameters for data collection from a portion of the plurality of
sensors, configure the hierarchical multiplexer, the ADCs and the
local storage to facilitate data collection based on the defined
parameters, and execute the data collection with the configured
elements including storing a set of data collected from a portion
of the plurality of sensors into the local storage. In embodiments,
the ADCs convert analog sensor data into a digital form that is
compatible with the hierarchical multiplexer. In embodiments, the
processor monitors at least one signal generated by the sensors for
a trigger condition and, upon detection of the trigger condition,
responds by at least one of communicating an alert over the
external interface and performing data acquisition according to a
template that corresponds to the trigger condition.
[0572] In embodiments, a system for data collection in an
industrial environment may include a hierarchical multiplexer that
may be configurable based on a data collection template of the
environment. The multiplexer may support receiving a large number
of data signals (e.g., from sensors in the environment)
simultaneously. In embodiments, all sensors for a portion of an
industrial machine in the environment may be individually connected
to inputs of a first stage of the multiplexer. The first stage of
the multiplexer may provide a plurality of outputs that may feed
into a second multiplexer stage. The second stage multiplexer may
provide multiple outputs that feed into a third stage, and so on.
Data collection templates for the environment may be configured for
certain data collection sets, such as a set to determine
temperature throughout a machine or a set to determine vibration
throughout a machine, and the like. Each template may identify a
plurality of sensors in the environment from which data is to be
collected, such as during a data collection event. When a template
is presented to the hierarchical multiplexer, mapping of inputs to
outputs for each multiplexing stage may be configured so that the
required data is available at output(s) of a final multiplexing
hierarchical stage for data collection. In an example, a data
collection template to collect a set of data to determine
temperature throughout a machine in the environment may identify
many temperature sensors. The first stage multiplexer may respond
to the template by selecting all of the available inputs that
connect to temperature sensors. The data from these sensors maybe
multiplexed onto multiple inputs of a second stage sensor that may
perform time-based multiplexing to produce a time-multiplexed
output(s) of temperature data from a portion of the sensors. These
outputs may be gathered by a data collector and de-multiplexed into
individual sensor temperature readings.
[0573] In embodiments, time-sensitive signals, such as triggers and
the like, may connect to inputs that directly connect to a final
multiplexer stage, thereby reducing any potential delay caused by
routing through multiple multiplexing stages.
[0574] In embodiments, a hierarchical multiplexer in a system for
data collection in an industrial environment may comprise an array
of relays, a programmable logic component, such as a CPLD, a field
programmable gate array (FPGA), and the like.
[0575] In embodiments, a system for data collection in an
industrial environment that may include a hierarchical multiplexer
for routing sensor outputs onto signal paths may be used with
explosive systems in mining applications. Blast initiating and
electronic blasting systems may be configured to provide computer
assisted blasting systems. Ensuring that blasting occurs safely may
involve effective sensing and analysis of a range of conditions. A
system for data collection in an industrial environment may be
deployed to sense and collect data associated with explosive
systems, such as explosive systems used for mining A data
collection system can use a hierarchical multiplexer to capture
data from explosive system installations automatically by aligning,
for example, a deployment of the explosive system including its
layout plans, integration, interconnectivity, cascading plan, and
the like with the hierarchical multiplexer. An explosive system may
be deployed with a form of hierarchy that starts with a primary
initiator and follows detonation connections through successive
layers of electronic blast control to sequenced detonation. Data
collected from each of these layers of blast systems configuration
may be associated with stages of a hierarchical multiplexer so that
data collected from bulk explosive detonation can be captured in a
hierarchy that corresponds to its blast control hierarchy.
[0576] In embodiments, a system for data collection in an
industrial environment that may include a hierarchical multiplexer
for routing sensor outputs onto signal paths may be used with
refinery blowers in oil and gas pipeline applications. Refinery
blower applications include fired heater combustion air preheat
systems and the like. Forced draft blowers may include a range of
moving and moveable parts that may benefit from condition sensing
and monitoring. Sensing may include detecting conditions of:
couplings (e.g., temperature, rotational rate, and the like);
motors (vibration, temperature, RPMs, torque, power usage, and the
like); louver mechanics (actuators, louvers, and the like); and
plenums (flow rate, blockage, back pressure, and the like). A
system for data collection in an industrial environment that uses a
hierarchical multiplexer for routing signals from sensors and the
like to data collectors may be configured to collect data from a
refinery blower. In an example, a plurality of sensors may be
deployed to sense air flow into, throughout, and out of a forced
draft blower used in a refinery application, such as to preheat
combustion air. Sensors may be grouped based on a frequency of a
signal produced by sensors. Sensors that detect louver position and
control may produce data at a lower rate than sensors that detect
blower RPMs. Therefore, louver position and control sensor signals
can be applied to a lower stage in a multiplexer hierarchy than the
blower RPM sensors because data from louvers change less often than
data from RPM sensors. A data collection system could switch among
a plurality of louver sensors and still capture enough information
to properly detect louver position. However, properly detecting
blower RPM data may require greater bandwidth of connection between
the blower RPM sensor and a data collector. A hierarchical
multiplexer may enable capturing blower RPM data at a rate that is
required for proper detection (perhaps by outputting the RPM sensor
data for long durations of time), while switching among several
louver sensor inputs and directing them onto (or through) an output
that is different than the blower RPM output. Alternatively, the
louver inputs may be time-multiplexed with the blower RPM data onto
a single output that can be de-multiplexed by a data collector that
is configured to determine when blower RPM data is being output and
when louver position data is being output.
[0577] In embodiments, a system for data collection in an
industrial environment that may include a hierarchical multiplexer
for routing sensor outputs onto signal paths may be used with
pipeline-related compressors (e.g., reciprocating) in oil and gas
pipeline applications. A typical use of a reciprocating compressor
for pipeline application is production of compressed air for
pipeline testing. A system for data collection in an industrial
environment may apply a hierarchical multiplexer while collecting
data from a pipeline testing-based reciprocating compressor. Data
from sensors deployed along a portion of a pipeline being tested
may be input to the lowest stage of the hierarchical multiplexer
because these sensors may be periodically sampled prior to and
during testing. However, the rate of sampling may be low relative
to sensors that detect compressor operation, such as parts of the
compressor that operate at higher frequencies, such as the
reciprocating linkage, motor, and the like. The sensors that
provide data at frequencies that enable reproduction of the
detected motion may be input to higher stages in the hierarchical
multiplexer. Time multiplexing among the pipeline sensors may
provide for coverage of a large number of sensors while capturing
events such as seal leakage and the like. However, time
multiplexing among reciprocating linkage sensors may require output
signal bandwidth that may exceed the bandwidth available for
routing data from the multiplexer to a data collector. Therefore,
in embodiments, a plurality of pipeline sensors may be
time-multiplexed onto a single multiplexer output and a compressor
sensor detecting rapidly moving parts, such as the compressor
motor, may be routed to separate outputs of the multiplexer.
[0578] Referring to FIG. 49, a system for data collection in an
industrial environment that uses a hierarchical multiplexer for
routing sensor signals to data collectors is depicted. Outputs from
a plurality of sensors, such as sensors that monitor conditions
that change with relatively low frequency (e.g., blower louver
position sensors) may be input to a lowest hierarchical stage 8000
of a hierarchical multiplexer 8002 and routed to successively
higher stages in the multiplexer, ultimately being output from the
multiplexer, perhaps as a time-multiplexed signal comprising
time-specific samples of each of the plurality of low frequency
sensors. Outputs from a second plurality of sensors, such as
sensors that monitor motor operation that may run at more than 1000
RPMs may be input to a higher hierarchical stage 8004 of the
hierarchical multiplexer and routed to outputs that support the
required bandwidth.
[0579] An example system for data collection in an industrial
environment includes a controller for controlling data collection
resources in the industrial environment and a hierarchical
multiplexer that facilitates successive multiplexing of a number of
input data channels according to a configurable hierarchy, wherein
the hierarchy is automatically configured by the controller based
on an operational parameter of a machine in the industrial
environment. In certain further embodiments, an example system
includes: where the operational parameter of the machine is
identified in a data collection template; where the hierarchy is
automatically configured in response to smart band data collection
activation further including an analog-to-digital converter
disposed between a source of the input data channels and the
hierarchical multiplexer; and/or where the operational parameter of
the machine comprises a trigger condition of at least one of the
data channels. Another example system for data collection in an
industrial environment includes a plurality of sensors and a
multiplexer module that receives sensor outputs from a first
portion of the sensors with similar output rates into separate
inputs of a first hierarchical multiplexer that provides at least
one multiplexed output of a portion of its inputs to a second
hierarchical multiplexer, the second hierarchical multiplexer
receiving sensor outputs from a second portion of the sensors and
providing at least one multiplexed output of a portion of its
inputs. In certain further embodiments, an example system includes:
where the second portion of the sensors output data at rates that
are higher than the output rates of the first portion of the
sensors; where the first portion and the second portion of the
sensors output data at different rates; where the first
hierarchical multiplexer output is a time-multiplexed combination
of a portion of its inputs; where the second multiplexer receives
sensor signals with output rates that are similar to a rate of
output of the first multiplexer; and/or where the first multiplexer
produces time-based multiplexing of the portion of its inputs.
[0580] An example system for data collection in an industrial
environment includes a number of sensors for sensing conditions of
a machine in the environment a hierarchical multiplexer, a number
of analog-to-digital converters, a controller, local storage, an
external interface, where the system includes using the controller
to access a data acquisition template that defines parameters for
data collection from a portion of the sensors, to configure the
hierarchical multiplexer, the ADCs, and the local storage to
facilitate data collection based on the defined parameters, and to
execute the data collection with the configured elements including
storing a set of data collected from a portion of the sensors into
the local storage. In certain further embodiments, an example
system includes: where the ADCs convert analog sensor data into a
digital form that is compatible with the hierarchical multiplexer;
where the processor monitors at least one signal generated by the
sensors for a trigger condition and, upon detection of the trigger
condition, responds by communicating an alert over the external
interface and/or performing data acquisition according to a
template that corresponds to the trigger condition; where the
hierarchical multiplexer performs successive multiplexing of data
received from the sensors according to a configurable hierarchy;
where the hierarchy is automatically configured by the controller
based on an operational parameter of a machine in the industrial
environment; where the operational parameter of the machine is
identified in a data collection template; where the hierarchy is
automatically configured in response to smart band data collection
activation; the system further including an ADC disposed between a
source of the input data channels and the hierarchical multiplexer;
where the operational parameter of the machine includes a trigger
condition of at least one of the data channels; where the
hierarchical multiplexer performs successive multiplexing of data
received from the plurality of sensors according to a configurable
hierarchy; and/or where the hierarchy is automatically configured
by a controller based on a detected parameter of an industrial
environment. Without limitation, n example system is configured for
monitoring a mining explosive system, and includes a controller for
controlling data collection resources associated with the explosive
system, and a hierarchical multiplexer that facilitates successive
multiplexing of a number of input data channels according to a
configurable hierarchy, where the hierarchy is automatically
configured by the controller based on a configuration of the
explosive system. Without limitation, an example system is
configured for monitoring a refinery blower in an oil and gas
pipeline applications, and includes a controller for controlling
data collection resources associated with the refinery blower, and
a hierarchical multiplexer that facilitates successive multiplexing
of a number of input data channels according to a configurable
hierarchy, where the hierarchy is automatically configured by the
controller based on a configuration of the refinery blower. Without
limitation, an example system is configured for monitoring a
reciprocating compressor in an oil and gas pipeline applications
comprising, and includes controller for controlling data collection
resources associated with the reciprocating compressor, and a
hierarchical multiplexer that facilitates successive multiplexing
of a number of input data channels according to a configurable
hierarchy, where the hierarchy is automatically configured by the
controller based on a configuration of the reciprocating
compressor.
[0581] In embodiments, a system for data collection in an
industrial environment may include an ultrasonic sensor disposed to
capture ultrasonic conditions of an element of in the environment.
The system may be configured to collect data representing the
captured ultrasonic condition in a computer memory, on which a
processor may execute an ultrasonic analysis algorithm. In
embodiments, the sensed element may be one of a moving element, a
rotating element, a structural element, and the like. In
embodiments, the data may be streamed to the computer memory. In
embodiments, the data may be continuously streamed. In embodiments,
the data may be streamed for a duration of time, such as an
ultrasonic condition sampling duration. In embodiments, the system
may also include a data routing infrastructure that facilitates
routing the streaming data from the ultrasonic sensor to a
plurality of destinations including local and remote destinations.
The routing infrastructure may include a hierarchical multiplexer
that is adapted to route the streaming data and data from at least
one other sensor to a destination.
[0582] In embodiments, ultrasonic monitoring in an industrial
environment may be performed by a system for data collection as
described herein on rotating elements (e.g., motor shafts and the
like), bearings, fittings, couplings, housings, load bearing
elements, and the like. The ultrasonic data may be used for pattern
recognition, state determination, time-series analysis, and the
like, any of which may be performed by computing resources of the
industrial environment, which may include local computing resources
(e.g., resources located within the environment and/or within a
machine in the environment, and the like) and remote computing
resources (e.g., cloud-based computing resources, and the
like).
[0583] In embodiments, ultrasonic monitoring in an industrial
environment by a system for data collection may be activated in
response to a trigger (e.g., a signal from a motor indicating the
motor is operational, and the like), a measure of time (e.g., an
amount of time since the most recent monitoring activity, a time of
day, a time relative to a trigger, an amount of time until a future
event, such as machine shutdown, and the like), an external event
(e.g., lightning strike, and the like). The ultrasonic monitoring
may be activated in response to implementation of a smart band data
collection activity. The ultrasonic monitoring may be activated in
response to a data collection template being applied in the
industrial environment. The data collection template may be
configured based on analysis of prior vibration-caused failures
that may be applicable to the monitored element, machine,
environment, and the like. Because continuous monitoring of
ultrasonic data may require dedicating data routing resources in
the industrial environment for extended periods of time, a data
collection template for continuous ultrasonic monitoring may be
configured with data routing and resource utilization setup
information that a controller of a data collection system may use
to setup the resources to accommodate continuous ultrasonic
monitoring. In an example, a data multiplexer may be configured to
dedicate a portion of its outputs to the ultrasonic data for a
duration of time specified in the template.
[0584] In embodiments, a system for data collection in an
industrial environment may perform continuous ultrasonic
monitoring. The system may also include processing of the
ultrasonic data by a local processor located proximal to the
vibration monitoring sensor or device(s). Depending on the
computing capabilities of the local processor, functions such as
peak detection may be performed. A programmable logic component may
provide sufficient computing capabilities to perform peak
detection. Processing of the ultrasonic data (local or remote) may
provide feedback to a controller associated with the element(s)
being monitored. The feedback may be used in a control loop to
potentially adjust an operating condition, such as rotational
speed, and the like, in an attempt to reduce or at least contain
potential negative impact suggested by the ultrasonic data
analysis.
[0585] In embodiments, a system for data collection in an
industrial environment may perform ultrasonic monitoring, and in
particular, continuous ultrasonic monitoring. The ultrasonic
monitoring data may be combined with multi-dimensional models of an
element or machine being monitored to produce a visualization of
the ultrasonic data. In embodiments, an image, set of images,
video, and the like may be produced that correlates in time with
the sensed ultrasonic data. In embodiments, image recognition
and/or analysis may be applied to ultrasonic visualizations to
further facilitate determining the severity of a condition detected
by the ultrasonic monitoring. The image analysis algorithms may be
trained to detect normal and out of bounds conditions. Data from
load sensors may be combined with ultrasonic data to facilitate
testing materials and systems.
[0586] In embodiments, a system for data collection in an
industrial environment may perform ultrasonic monitoring of a
pipeline in an oil and gas pipeline application. Flows of petroleum
through pipelines can create vibration and other mechanical effects
that may contribute to structural changes in a liner of the
pipeline, support members, flow boosters, regulators, diverters,
and the like. Performing continuous ultrasonic monitoring of key
elements in a pipeline may facilitate detecting early changes in
material, such as joint fracturing, and the like, that may lead to
failure. A system for data collection in an industrial environment
may be configured with ultrasonic sensing devices that may be
connected through signal data routing resources, such as crosspoint
switches, multiplexers, and the like, to data collection and
analysis nodes at which the collected ultrasonic data can be
collected and analyzed. In embodiments, a data collection system
may include a controller that may reference a data collection plan
or template that includes information to facilitate configuring the
data sampling, routing, and collection resources of the system to
accommodate collecting ultrasonic sample data from a plurality of
elements along the pipeline. The template may indicate a sequence
for collecting ultrasonic data from a plurality of ultrasonic
sensors and the controller may configure a multiplexer to route
ultrasonic sensor data from a specified ultrasonic sensor to a
destination, such as a data storage controller, analysis processor
and the like, for a duration specified in the template. The
controller may detect a sequence of collection in the template, or
a sequence of templates to access, and respond to each template in
the detected sequence, adjusting the multiplexer and the like to
route the sensor data specified in each template to a
collector.
[0587] In embodiments, a system for data collection in an
industrial environment may perform ultrasonic monitoring of
compressors in a power generation application. Compressors include
several critical rotating elements (e.g., shaft, motor, and the
like), rotational support elements (e.g., bearings, couplings, and
the like), and the like. A system for data collection configured to
facilitate sensing, routing, collection and analysis of ultrasonic
data in a power generation application may receive ultrasonic
sensor data from a plurality of ultrasonic sensors. Based on a
configuration setup template, such as a template for collecting
continuous ultrasonic data from one or more ultrasonic sensor
devices, a controller may configure resources of the data
collection system to facilitate delivery of the ultrasonic data
over one or more signal data lines from the sensor(s) at least to
data collectors that may be locally or remotely accessible. In
embodiments, a template may indicate that ultrasonic data for a
main shaft should be retrieved continuously for one minute, and
then ultrasonic data for a secondary shaft should be retrieved for
another minute, followed by ultrasonic data for a housing of the
compressor. The controller may configure a multiplexer that
receives the ultrasonic data for each of these sensors to route the
data from each sensor in order by configuring a control set that
initially directs the inputs from the main shaft ultrasonic sensors
through the multiplexer until the time or other measure of data
being forwarded is reached. The controller could switch the
multiplexer to route the additional ultrasonic data as required to
satisfy the second template requirements. The controller may
continue adjusting the data collection system resources along the
way until all of the ultrasonic monitoring data collection
templates are satisfied.
[0588] In embodiments, a system for data collection in an
industrial environment may perform ultrasonic monitoring of wind
turbine gearboxes in a wind energy generation application.
Gearboxes in wind turbines may experience a high degree of
resistance in operation, due in part to the changing nature of
wind, which may cause moving parts, such as the gear planes,
hydraulic fluid pumps, regulators, and the like, to prematurely
fail. A system for data collection in an industrial environment may
be configured with ultrasonic sensors that capture information that
may lead to early detection of potential failure modes of these
high-strain elements. To ensure that ultrasonic data may be
effectively acquired from several different ultrasonic sensors with
sufficient coverage to facilitate producing an actionable
ultrasonic imaging assessment, the system may be configured
specifically to deliver sufficient data at a relatively high rate
from one or more of the sensors. Routing channel(s) may be
dedicated to transferring ultrasonic sensing data for a duration of
time that may be specified in an ultrasonic data collection plan or
template. To accomplish this, a controller, such as a programmable
logic component, may configure a portion of a crosspoint switch and
data collectors to deliver ultrasonic data from a first set of
ultrasonic sensors (e.g., those that sense hydraulic fluid flow
control elements) to a plurality of data collectors. Another
portion of the crosspoint switch may be configured to route
additional sensor data that may be useful for evaluating the
ultrasonic data (e.g., motor on/off state, thermal condition of
sensed parts, and the like) on other data channels to data
collectors where the data can be combined and analyzed. The
controller may reconfigure the data routing resources to enable
collecting ultrasonic data from other elements based on a
corresponding data collection template.
[0589] Referring to FIG. 50, a system for data collection in an
industrial environment may include one or more ultrasonic sensors
8050 that may connect to a data collection and routing system 8052
that may be configured by a controller 8054 based on an ultrasonic
sensor-specific data collection template 8056 that may be provided
to the controller 8054 by an ultrasonic data analysis facility
8058. The controller 8054 may configure resources of the data
collection system 8052 and monitor the data collection fur a
duration of time based on the requirements for data collection in
the template 8056.
[0590] An example system for data collection in an industrial
environment includes an ultrasonic sensor disposed to capture
ultrasonic conditions of an element in the environment, a
controller that configures data routing resources of the data
collection system to route ultrasonic data being captured by the
ultrasonic sensor to a destination location that is specified by an
ultrasonic monitoring data collection template, and a processor
executing an ultrasonic analysis algorithm on the data after
arrival at the destination. In certain further embodiments, an
example system includes: where the template defines a time interval
of continuous ultrasonic data capture from the ultrasonic sensor; a
data routing infrastructure that facilitates routing the streaming
data from the ultrasonic sensor to a number of destinations
including local and remote destinations; the routing infrastructure
including a hierarchical multiplexer that is adapted to route the
streaming data and data from at least one other sensor to a
destination; where the element in the environment includes rotating
elements, bearings, fittings, couplings, housing, and/or load
bearing parts; where the template defines a condition of activation
of continuous ultrasonic monitoring; and/or where the condition of
activation includes a trigger, a smart-band, a template, an
external event, and/or a regulatory compliance configuration.
[0591] An example system for data collection in an industrial
environment includes an ultrasonic sensor disposed to capture
ultrasonic conditions of an element of an industrial machine in the
environment, a controller that configures data routing resources of
the data collection system to route ultrasonic data being captured
by the ultrasonic sensor to a destination location that is
specified by an ultrasonic monitoring data collection template, and
a processor executing an ultrasonic analysis algorithm on the data
after arrival at the destination. In certain embodiments, an
example system further includes: wherein the template defines a
time interval of continuous ultrasonic data capture from the
ultrasonic sensor; the system further including a data routing
infrastructure that facilitates routing the data from the
ultrasonic sensor to a number of destinations including local and
remote destinations; the data routing infrastructure including a
hierarchical multiplexer that is adapted to route the ultrasonic
data and data from at least one other sensor to a destination;
where the element of the industrial machine includes rotating
elements, bearings, fittings, couplings, housing, and/or load
bearing parts; where the template defines a condition of activation
of continuous ultrasonic monitoring; and/or where the condition of
activation includes a trigger, a smart-band, a template, an
external event, and/or a regulatory compliance configuration.
[0592] An example method of continuous ultrasonic monitoring in an
industrial environment includes disposing an ultrasonic monitoring
device within ultrasonic monitoring range of at least one moving
part of an industrial machine in the industrial environment, the
ultrasonic monitoring device producing a stream of ultrasonic
monitoring data, configuring, based on an ultrasonic monitoring
data collection template, a data routing infrastructure to route
the stream of ultrasonic monitoring data to a destination, where
the infrastructure facilitates routing data from a number of
sensors through at an analog crosspoint switch and/or a
hierarchical multiplexer, to a number of destinations, routing the
ultrasonic monitoring device data through the routing
infrastructure to a destination; processing the stored data with an
ultrasonic data analysis algorithm that provides an ultrasonic
analysis of at least one of a motor shaft, bearings, fittings,
couplings, housing, and load bearing parts; and/or storing the data
in a computer accessible memory at the destination. Certain further
embodiments of an example method include: where the data collection
template defines a time interval of continuous ultrasonic data
capture from the ultrasonic monitoring device; where configuring
the data routing infrastructure includes configuring the
hierarchical multiplexer to route the ultrasonic data and data from
at least one other sensor to a destination; where ultrasonic
monitoring is performed on at least one element in an industrial
machine that includes rotating elements, bearings, fittings,
couplings, a housing, and/or load bearing parts; where the template
defines a condition of activation of continuous ultrasonic
monitoring; where the condition of activation includes a trigger, a
smart-band, a template, an external event, and/or a regulatory
compliance configuration; where the ultrasonic data analysis
algorithm performs pattern recognition; and/or where routing the
ultrasonic monitoring device data is in response to detection of a
condition in the industrial environment associated with the at
least one moving part.
[0593] Without limitation, an example system for monitoring an oil
or gas pipeline includes a processor executing an ultrasonic
analysis algorithm on the pipeline data after arrival at the
destination; an example system for monitoring a power generation
compressor includes a processor executing an ultrasonic analysis
algorithm on the power generation compressor data after arrival at
the destination; and an example system for monitoring a wind
turbine gearbox includes a processor executing an ultrasonic
analysis algorithm on the gearbox data after arrival at the
destination.
[0594] Industrial components such as pumps, compressors, air
conditioning units, mixers, agitators, motors, and engines may play
critical roles in the operation of equipment in a variety of
environments including as part of manufacturing equipment in
industrial environments such as factories, gas handling systems,
mining operations, automotive systems, and the like.
[0595] There are a wide variety of pumps such as a variety of
positive displacement pumps, velocity pumps, and impulse pumps.
Velocity or centrifugal pumps typically comprise an impeller with
curved blades which, when an impeller is immersed in a fluid, such
as water or a gas, causes the fluid or gas to rotate in the same
rotational direction as the impeller. As the fluid or gas rotates,
centrifugal force causes it to move to the outer diameter of the
pump, e.g., the pump housing, where it can be collected and further
processed. The removal of the fluid or gas from the outer
circumference may result in lower pressure at a pump input orifice
causing new fluid or gas to be drawn into the pump.
[0596] Positive displacement pumps may comprise reciprocating
pumps, progressive cavity pumps, gear or screw pumps, such as
reciprocating pumps typically comprise a piston which alternately
creates suction, which opens an inlet valve and draws a liquid or
gas into a cylinder, and pressure, which closes the inlet valve and
forces the liquid or gas present out of the cylinder through an
outlet valve. This method of pumping may result in periodic waves
of pressurized liquid or gas being introduced into the downstream
system.
[0597] Some automotive vehicles such as cars and trucks may use a
water cooling system to keep the engine from overheating. In some
automobiles, a centrifugal water pump, driven by a belt associated
with a driveshaft of the vehicle, is used to force a mixture of
water and coolant through the engine to maintain an acceptable
engine temperature. Overheating of the engine may be highly
destructive to the engine and yet it may be difficult or costly to
access a water pump installed in a vehicle.
[0598] In embodiments, a vehicle water pump may be equipped with a
plurality of sensors for measuring attributes associated with the
water pump such as temperature of bearings or pump housing,
vibration of a driveshaft associated with the pump, liquid leakage,
and the like. These sensors may be connected either directly to a
monitoring device or through an intermediary device using a mix of
wired and wireless connection techniques. A monitoring device may
have access to detection values corresponding to the sensors where
the detection values correspond directly to the sensor output or a
processed version of the data output such as a digitized or sampled
version of the sensor output, and/or a virtual sensor or modeled
value correlated from other sensed values. The monitoring device
may access and process the detection values using methods discussed
elsewhere herein to evaluate the health of the water pump and
various components of the water pump prone to wear and failure,
e.g., bearings or sets of bearings, drive shafts, motors, and the
like. The monitoring device may process the detection values to
identify a torsion of the drive shaft of the pump. The identified
torsion may then be evaluated relative to expected torsion based on
the specific geometry of the water pump and how it is installed in
the vehicle. Unexpected torsion may put undue stress on the
driveshaft and may be a sign of deteriorating health of the pump.
The monitoring device may process the detection values to identify
unexpected vibrations in the shaft or unexpected temperature values
or temperature changes in the bearings or in the housing in
proximity to the bearings. In some embodiments, the sensors may
include multiple temperature sensors positioned around the water
pump to identify hot spots among the bearings or across the pump
housing which might indicate potential bearing failure. The
monitoring device may process the detection values associated with
water sensors to identify liquid leakage near the pump which may
indicate a bad seal. The detection values may be jointly analyzed
to provide insight into the health of the pump.
[0599] In an illustrative example, detection values associated with
a vehicle water pump may show a sudden increase in vibration at a
higher frequency than the operational rotation of the pump with a
corresponding localized increase of temperature associated with a
specific phase in the pump cycle. Together these may indicate a
localized bearing failure.
[0600] Production lines may also include one or more pumps for
moving a variety of material including acidic or corrosive
materials, flammable materials, minerals, fluids comprising
particulates of varying sizes, high viscosity fluids, variable
viscosity fluids, or high-density fluids. Production line pumps may
be designed to specifically meet the needs of the production line
including pump composition to handle the various material types, or
torque needed to move the fluid at the desired speed or with the
desired pressure. Because these production lines may be continuous
process lines, it may be desirable to perform proactive maintenance
rather than wait for a component to fail. Variations in pump speed
and pressure may have the potential to negatively impact the final
product, and the ability to identify issues in the final product
may lag the actual component deterioration by an unacceptably long
period.
[0601] In embodiments, an industrial pump may be equipped with a
plurality of sensors for measuring attributes associated with the
pump such as temperature of bearings or pump housing, vibration of
a driveshaft associated with the pump, vibration of input or output
lines, pressure, flow rate, fluid particulate measures, vibrations
of the pump housing, and the like. These sensors may be connected
either directly to a monitoring device or through an intermediary
device using a mix of wired and wireless connection techniques. A
monitoring device may have access to detection values corresponding
to the sensors where the detection values correspond directly to
the sensor output of a processed version of the data output such as
a digitized or sampled version of the sensor output. The monitoring
device may access and process the detection values using methods
discussed elsewhere herein to evaluate the health of the pump
overall, evaluate the health of pump components, predict potential
down line issues arising from atypical pump performance, or changes
in fluid being pumped. The monitoring device may process the
detection values to identify torsion on the drive shaft of the
pump. The identified torsion may then be evaluated relative to
expected torsion based on the specific geometry of the pump and how
it is installed in the equipment relative to other components on
the assembly line. Unexpected torsion may put undue stress on the
driveshaft and may be a sign of deteriorating health of the pump.
Vibration of the inlet and outlet pipes may also be evaluated for
unexpected or resonant vibrations which may be used to drive
process controls to avoid certain pump frequencies. Changes in
vibration may also be due to changes in fluid composition or
density, amplifying or dampening vibrations at certain frequencies.
The monitoring device may process the detection values to identify
unexpected vibrations in the shaft, unexpected temperature values,
or temperature changes in the bearings or in the housing in
proximity to the bearings. In some embodiments, the sensors may
include multiple temperature sensors positioned around the pump to
identify hot spots among the bearings or across the pump housing
which might indicated potential bearing failure. For some pumps,
when the fluid being pumped is corrosive or contains large amounts
of particulates, there may be damage to the interior components of
the pump in contact with the fluid due to cumulative exposure to
the fluid. This may be reflected in unanticipated variations in
output pressure. Additionally or alternatively, if a gear in a gear
pump begins to corrode and no longer forces all the trapped fluid
out this may result in increased pump speed, fluid cavitation,
and/or unexpected vibrations in the output pipe.
[0602] Compressors increase the pressure of a gas by decreasing the
volume occupied by the gas or increasing the amount of the gas in a
confined volume. There may be positive-displacement compressors
that utilize the motion of pistons or rotary screws to move the gas
into a pressurized holding chamber. There are dynamic displacement
gas compressors that use centrifugal force to accelerate the gas
into a stationary compressor where the kinetic energy is converted
to pressure. Compressors may be used to compress various gases for
use on an assembly line. Compressed air may power pneumatic
equipment on an assembly line. In the oil and gas industry, flash
gas compressors may be used to compress gas so that it leaves a
hydrocarbon liquid when it enters a lower pressure environment.
Compressors may be used to restore pressure in gas and oil
pipelines, to mix fluids of interest, and/or to transfer or
transport fluids of interest. Compressors may be used to enable the
underground storage of natural gas.
[0603] Like pumps, compressors may be equipped with a plurality of
sensors for measuring attributes associated with the compressor
such as temperature of bearings or compressor housing, vibration of
a driveshaft, transmission, gear box and the like associated with
the compressor, vessel pressure, flow rate, and the like. These
sensors may be connected either directly to a monitoring device or
through an intermediary device using a mix of wired and wireless
connection techniques. A monitoring device may have access to
detection values corresponding to the sensors where the detection
values correspond directly to the sensor output of a processed
version of the data output such as a digitized or sampled version
of the sensor output. The monitoring device may access and process
the detection values using methods described elsewhere herein to
evaluate the health of the compressor overall, evaluate the health
of compressor components and/or predict potential down line issues
arising from atypical compressor performance. The monitoring device
may process the detection values to identify torsion on a
driveshaft of the compressor. The identified torsion may then be
evaluated relative to expected torsion based on the specific
geometry of the compressor and how it is installed in the equipment
relative to other components and pieces of equipment. Unexpected
torsion may put undue stress on the driveshaft and may be a sign of
deteriorating health of the compressor. Vibration of the inlet and
outlet pipes may also be evaluated for unexpected or resonant
vibrations which may be used to drive process controls to avoid
certain compressor frequencies. The monitoring device may process
the detection values to identify unexpected vibrations in the
shaft, unexpected temperature values or temperature changes in the
bearings or in the housing in proximity to the bearings. In some
embodiments, the sensors may include multiple temperature sensors
positioned around the compressor to identify hot spots among the
bearings or across the compressor housing, which might indicate
potential bearing failure. In some embodiments, sensors may monitor
the pressure in a vessel storing the compressed gas. Changes in the
pressure or rate of pressure change may be indicative of problems
with the compressor.
[0604] Agitators and mixers are used in a variety of industrial
environments. Agitators may be used to mix together different
components such as liquids, solids, or gases. Agitators may be used
to promote a more homogenous mixture of component materials.
Agitators may be used to promote a chemical reaction by increasing
exposure between different component materials and adding energy to
the system. Agitators may be used to promote heat transfer to
facilitate uniform heating or cooling of a material.
[0605] Mixers and agitators are used in such diverse industries as
chemical production, food production, pharmaceutical production,
and the like. There are paint and coating mixers, adhesive and
sealant mixers, oil and gas mixers, water treatment mixers,
wastewater treatment mixers, and the like.
[0606] Agitators may comprise equipment that rotates or agitates an
entire tank or vessel in which the materials to be mixed are
located, such as a concrete mixer. Effective agitations may be
influenced by the number and shape of baffles in the interior of
the tank. Agitation by rotation of the tank or vessel may be
influenced by the axis of rotation relative to the shape of the
tank, direction of rotation, and external forces such as gravity
acting on the material in the tank. Factors affecting the efficacy
of material agitation or mixing by agitation of the tank or vessel
may include axes of rotation, and amplitude and frequency of
vibration along different axes. These factors may be selected based
on the types of materials being selected, their relative
viscosities, specific gravities, particulate count, any shear
thinning or shear thickening anticipated for the component
materials or mixture, flow rates of material entering or exiting
the vessel or tank, direction and location of flows of material
entering of exiting the vessel, and the like.
[0607] Agitators, large tank mixers, portable tank mixers, tote
tank mixers, drum mixers, and mounted mixers (with various mount
types) may comprise a propeller or other mechanical device such as
a blade, vane, or stator inserted into a tank of materials to be
mixed, while rotating a propeller or otherwise moving a mechanical
device. These may include airfoil impellers, fixed pitch blade
impellers, variable pitch blade impellers, anti-ragging impellers,
fixed radial blade impellers, marine-type propellers, collapsible
airfoil impellers, collapsible pitched blade impellers, collapsible
radial blade impellers, and variable pitch impellers. Agitators may
be mounted such that the mechanical agitation is centered in the
tank. Agitators may be mounted such that they are angled in a tank
or are vertically or horizontally offset from the center of the
vessel. The agitators may enter the tank from above, below, or the
side of the tank. There may be a plurality of agitators in a single
tank to achieve uniform mixing throughout the tank or container of
chemicals.
[0608] Agitators may include the strategic flow or introduction of
component materials into the vessel including the location and
direction of entry, rate of entry, pressure of entry, viscosity of
material, specific gravity of the material, and the like.
[0609] Successful agitation of mixing of materials may occur with a
combination of techniques such as one or more propellers in a
baffled tank where components are being introduced at different
locations and at different rates.
[0610] In embodiments, an industrial mixer or agitator may be
equipped with a plurality of sensors for measuring attributes
associated with the industrial mixer such as: temperature of
bearings or tank housing, vibration of driveshafts associated with
a propeller or other mechanical device such as a blade, vane or
stator, vibration of input or output lines, pressure, flow rate,
fluid particulate measures, vibrations of the tank housing and the
like. These sensors may be connected either directly to a
monitoring device or through an intermediary device using a mix of
wired and wireless connection techniques. A monitoring device may
have access to detection values corresponding to the sensors where
the detection values correspond directly to the sensor output of a
processed version of the data, output such as a digitized or
sampled version of the sensor output, fusion of data from multiple
sensors, and the like. The monitoring device may access and process
the detection values using methods discussed elsewhere herein to
evaluate the health of the agitator or mixer overall, evaluate the
health of agitator or mixer components, predict potential down line
issues arising from atypical performance or changes in composition
of material being agitated. For example, the monitoring device may
process the detection values to identify torsion on the driveshaft
of an agitating impeller. The identified torsion may then be
evaluated relative to expected torsion based on the specific
geometry of the agitator and how it is installed in the equipment
relative to other components and/or pieces of equipment. Unexpected
torsion may put undue stress on the driveshaft and may be a sign of
deteriorating health of the agitator. Vibration of inflow and
outflow pipes may be monitored for unexpected or resonant
vibrations which may be used to drive process controls to avoid
certain agitation frequencies. Inflow and outflow pipes may also be
monitored for unexpected flow rates, unexpected particulate
content, and the like. Changes in vibration may also be due to
changes in fluid composition, or density amplifying or dampening
vibrations at certain frequencies. The monitoring device may
distribute sensors to collect detection values which may be used to
identify unexpected vibrations in the shaft, or unexpected
temperature values or temperature changes in the bearings or in the
housing in proximity to the bearings. For some agitators, when the
fluid being agitated is corrosive or contains large amounts of
particulates, there may be damage to the interior components of the
agitator (e.g., baffles, propellers, blades, and the like) which
are in contact with the materials, due to cumulative exposure to
the materials.
[0611] HVAC, air-conditioning systems, and the like may use a
combination of compressors and fans to cool and circulate air in
industrial environments. Similar to the discussion of compressors
and agitators, these systems may include a number of rotating
components whose failure or reduced performance might negatively
impact the working environment and potentially degrade product
quality. A monitoring device may be used to monitor sensors
measuring various aspects of the one or more rotating components,
the venting system, environmental conditions, and the like.
Components of the HVAC/air-conditioning systems may include fan
motors, driveshafts, bearings, compressors, and the like. The
monitoring device may access and process the detection values
corresponding to the sensor outputs according to methods discussed
elsewhere herein to evaluate the overall health of the
air-conditioning unit, HVAC system, and like as well as components
of these systems, identify operational states, predict potential
issues arising from atypical performance, and the like. Evaluation
techniques may include bearing analysis, torsional analysis of
driveshafts, rotors and stators, peak value detection, and the
like. The monitoring device may process the detection values to
identify issues such as torsion on a driveshaft, potential bearing
failures, and the like.
[0612] Assembly line conveyors may comprise a number of moving and
rotating components as part of a system for moving material through
a manufacturing process. These assembly line conveyors may operate
over a wide range of speeds. These conveyances may also vibrate at
a variety of frequencies as they convey material horizontally to
facilitate screening, grading, laning for packaging, spreading,
dewatering, feeding product into the next in-line process, and the
like.
[0613] Conveyance systems may include engines or motors, one or
more driveshafts turning rollers or bearings along which a conveyor
belt may move. A vibrating conveyor may include springs and a
plurality of vibrators which vibrate the conveyor forward in a
sinusoidal manner.
[0614] In embodiments, conveyors and vibrating conveyors may be
equipped with a plurality of sensors for measuring attributes
associated with the conveyor such as temperature of bearings,
vibration of driveshafts, vibrations of rollers along which the
conveyor travels, velocity and speed associated with the conveyor,
and the like. The monitoring device may access and process the
detection values using methods discussed elsewhere herein to
evaluate the overall health of the conveyor as well as components
of the conveyor, predict potential issues arising from atypical
performance, and the like. Techniques for evaluating the conveyors
may include bearing analysis, torsional analysis, phase
detection/phase lock loops to align detection values from different
parts of the conveyor, frequency transformations and frequency
analysis, peak value detection, and the like. The monitoring device
may process the detection values to identify torsion on a
driveshaft, potential bearing failures, uneven conveyance and
like.
[0615] In an illustrative example, a paper-mill conveyance system
may comprise a mesh onto which the paper slurry is coated. The mesh
transports the slurry as liquid evaporates and the paper dries. The
paper may then be wound onto a core until the roll reaches
diameters of up to three meters. The transport speeds of the
paper-mill range from traditional equipment operating at 14-48
meters/minute to new, high-speed equipment operating at close to
2000 meters/minute. For slower machines, the paper may be winding
onto the roll at 14 meters/minute which, towards the end of the
roll having a diameter of approximately three meters would indicate
that the take up roll may be rotating at speeds on the order of a
couple of rotations a minute. Vibrations in the web conveyance or
torsion across the take up roller may result in damage to the
paper, skewing of the paper on the web, or skewed rolls which may
result in equipment downtime or product that is lower in quality or
unusable. Additionally, equipment failure may result in costly
machine shutdowns and loss of product. Therefore, the ability to
predict problems and provide preventative maintenance and the like
may be useful.
[0616] Monitoring truck engines and steering systems to facilitate
timely maintenance and avoid unexpected breakdowns may be
important. Health of the combustion chamber, rotating crankshafts,
bearings, and the like may be monitored using a monitoring device
structured to interpret detection values received from a plurality
of sensors measuring a variety of characteristics associated with
engine components including temperature, torsion, vibration, and
the like. As discussed above, the monitoring device may process the
detection values to identify engine bearing health, torsional
vibrations on a crankshaft/driveshaft, unexpected vibrations in the
combustion chambers, overheating of different components, and the
like. Processing may be done locally or data may be collected
across a number of vehicles and jointly analyzed. The monitoring
device may process detection values associated with the engine,
combustion chambers, and the like. Sensors may monitor temperature,
vibration, torsion, acoustics, and the like to identify issues. A
monitoring device or system may use techniques such as peak
detection, bearing analysis, torsion analysis, phase detection,
PLL, band pass filtering, and the like to identify potential issues
with the steering system and bearing and torsion analysis to
identify potential issues with rotating components on the engine.
This identification of potential issues may be used to schedule
timely maintenance, reduce operation prior to maintenance, and
influence future component design.
[0617] Drilling machines and screwdrivers in the oil and gas
industries may be subjected to significant stresses. Because they
are frequently situated in remote locations, an unexpected
breakdown may result in extended down time due to the lead-time
associated with bringing in replacement components. The health of a
drilling machine or screwdriver and associated rotating
crankshafts, bearings, and the like may be monitored using a
monitoring device structured to interpret detection values received
from a plurality of sensors measuring a variety of characteristics
associated with the drilling machine or screwdriver including
temperature, torsion, vibration, rotational speed, vertical speed,
acceleration, image sensors, and the like. As discussed above, the
monitoring device may process the detection values to identify
equipment health, torsional vibrations on a crankshaft/driveshaft,
unexpected vibrations in the component, overheating of different
components, and the like. Processing may be done locally or data
collected across a number of machines and jointly analyzed. The
monitoring device may jointly process detection values, equipment
maintenance records, product records, historical data, and the like
to identify correlations between detection values, current and
future states of the component, anticipated lifetime of the
component or piece of equipment, and the like. Sensors may monitor
temperature, vibration, torsion, acoustics, and the like to
identify issues such as unanticipated torsion in the drill shaft,
slippage in the gears, overheating, and the like. A monitoring
device or system may use techniques such as peak detection, bearing
analysis, torsion analysis, phase detection, PLL, band pass
filtering, and the like to identify potential issues. This
identification of potential issues may be used to schedule timely
maintenance, order new or replacement components, reduce operation
prior to maintenance, and influence future component design.
[0618] Similarly, it may be desirable to monitor the health of
gearboxes operating in an oil and gas field. A monitoring device
may be structured to interpret detection values received from a
plurality of sensors measuring a variety of characteristics
associated with the gearbox such as temperature, vibration, and the
like. The monitoring device may process the detection values to
identify gear and gearbox health and anticipated life. Processing
may be done locally or data collected across a number of gearboxes
and jointly analyzed. The monitoring device may jointly process
detection values, equipment maintenance records, product records
historical data, and the like to identify correlations between
detection values, current and future states of the gearbox,
anticipated lifetime of the gearbox and associated components, and
the like. A monitoring device or system may use techniques such as
peak detection, bearing analysis, torsion analysis, phase
detection, PLL, band pass filtering, to identify potential issues.
This identification of potential issues may be used to schedule
timely maintenance, order new or replacement components, reduce
operation prior to maintenance, and influence future equipment
design.
[0619] Refining tanks in the oil and gas industries may be
subjected to significant stresses due to the chemical reactions
occurring inside. Because a breach in a tank could result in the
release of potentially toxic chemicals, it may be beneficial to
monitor the condition of the refining tank and associated
components. Monitoring a refining tank to collect a variety of
ongoing data may be used to predict equipment wear, component wear,
unexpected stress, and the like. Given predictions about equipment
health, such as the status of a refining tank, may be used to
schedule timely maintenance, order new or replacement components,
reduce operation prior to maintenance, and influence future
component design. Similar to the discussion above, a refining tank
may be monitored using a monitoring device structured to interpret
detection values received from a plurality of sensors measuring a
variety of characteristics associated with the refining tank such
as temperature, vibration, internal and external pressure, the
presence of liquid or gas at seams and ports, and the like. The
monitoring device may process the detection values to identify
equipment health, unexpected vibrations in the tank, overheating of
the tank or uneven heating across the tank, and the like.
Processing may be done locally or data collected across a number of
tanks and jointly analyzed. The monitoring device may jointly
process detection values, equipment maintenance records, product
records historical data, and the like to identify correlations
between detection values, current and future states of the tank,
anticipated lifetime of the tank and associated components, and the
like. A monitoring device or system may use techniques such as peak
detection, bearing analysis, torsion analysis, phase detection,
PLL, band pass filtering, and the like to identify potential
issues.
[0620] Similarly, it may be desirable to monitor the health of
centrifuges operating in an oil and gas refinery. A monitoring
device may be structured to interpret detection values received
from a plurality of sensors measuring a variety of characteristics
associated with the centrifuge such as temperature, vibration,
pressure, and the like. The monitoring device may process the
detection values to identify equipment health, unexpected
vibrations in the centrifuge, overheating, pressure across the
centrifuge, and the like. Processing may be done locally or data
collected across a number of centrifuges and jointly analyzed. The
monitoring device may jointly process detection values, equipment
maintenance records, product records historical data, and the like
to identify correlations between detection values, current and
future states of the centrifuge, anticipated lifetime of the
centrifuge and associated components, and the like. A monitoring
device or system may use techniques such as peak detection, bearing
analysis, torsion analysis, phase detection, PLL, band pass
filtering, to identify potential issues. This identification of
potential issues may be used to schedule timely maintenance, order
new or replacement components, reduce operation prior to
maintenance and influence future equipment design.
[0621] In embodiments, information about the health or other status
or state information of or regarding a component or piece of
industrial equipment may be obtained by monitoring the condition of
various components throughout a process. Monitoring may include
monitoring the amplitude of a sensor signal measuring attributes
such as temperature, humidity, acceleration, displacement, and the
like. An embodiment of a data monitoring device 8100 is shown in
FIG. 51 and may include a plurality of sensors 8106 communicatively
coupled to a controller 8102. The controller 8102 may include a
data acquisition circuit 8104, a data analysis circuit 8108, a MUX
control circuit 8114, and a response circuit 8110. The data
acquisition circuit 8104 may include a MUX 8112 where the inputs
correspond to a subset of the detection values. The MUX control
circuit 8114 may be structured to provide adaptive scheduling of
the logical control of the MUX and the correspondence of MUX input
and detected values based on a subset of the plurality of detection
values and/or a command from the response circuit 8110 and/or the
output of the data analysis circuit 8104. The data analysis circuit
8108 may comprise one or more of a peak detection circuit, a phase
differential circuit, a PLL circuit, a bandpass filter circuit, a
frequency transformation circuit, a frequency analysis circuit, a
torsional analysis circuit, a bearing analysis circuit, an overload
detection circuit, a sensor fault detection circuit, a vibrational
resonance circuit for the identification of unfavorable interaction
among machines or components, a distortion identification circuit
for the identification of unfavorable distortions such as
deflections shapes upon operation, overloading of weight, excessive
forces, stress and strain-based effects, and the like. The data
analysis circuit 8108 may output a component health status as a
result of the analysis.
[0622] The data analysis circuit 8108 may determine a state,
condition, or status of a component, part, sub-system, or the like
of a machine, device, system or item of equipment (collectively
referred to herein as a component health status) based on a maximum
value of a MUX output for a given input or a rate of change of the
value of a MUX output for a given input. The data analysis circuit
8108 may determine a component health status based on a time
integration of the value of a MUX for a given input. The data
analysis circuit 8108 may determine a component health status based
on phase differential of MUX output relative to an on-board time or
another sensor. The data analysis circuit 8108 may determine a
component health status based on a relationship of value, phase,
phase differential, and rate of change for MUX outputs
corresponding to one or more input detection values. The data
analysis circuit 8108 may determine a component health status based
on process stage or component specification or component
anticipated state.
[0623] The multiplexer control circuit 8114 may adapt the
scheduling of the logical control of the multiplexer based on a
component health status, an anticipated component health status,
the type of component, the type of equipment being measured, an
anticipated state of the equipment, a process stage (different
parameters/sensor values) may be important at different stages in a
process. The multiplexer control circuit 8114 may adapt the
scheduling of the logical control of the multiplexer based on a
sequence selected by a user or a remote monitoring application, or
on the basis of a user request for a specific value. The
multiplexer control circuit 8114 may adapt the scheduling of the
logical control of the multiplexer based on the basis of a storage
profile or plan (such as based on type and availability of storage
elements and parameters as described elsewhere in this disclosure
and in the documents incorporated herein by reference), network
conditions or availability (also as described elsewhere in this
disclosure and in the documents incorporated herein by reference),
or value or cost of component or equipment.
[0624] The plurality of sensors 8106 may be wired to ports on the
data acquisition circuit 8104. The plurality of sensors 8106 may be
wirelessly connected to the data acquisition circuit 8104. The data
acquisition circuit 8104 may be able to access detection values
corresponding to the output of at least one of the plurality of
sensors 8106 where the sensors 8106 may be capturing data on
different operational aspects of a piece of equipment or an
operating component.
[0625] The selection of the plurality of sensors 8106 for a data
monitoring device 8100 designed for a specific component or piece
of equipment may depend on a variety of considerations such as
accessibility for installing new sensors, incorporation of sensors
in the initial design, anticipated operational and failure
conditions, resolution desired at various positions in a process or
plant, reliability of the sensors, and the like. The impact of a
failure, time response of a failure (e.g., warning time and/or
off-nominal modes occurring before failure), likelihood of failure,
and/or sensitivity required, and/or difficulty to detect failure
conditions may drive the extent to which a component or piece of
equipment is monitored with more sensors, and/or higher capability
sensors being dedicated to systems where unexpected or undetected
failure would be costly or have severe consequences.
[0626] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating, and
the like, sensors 8106 may comprise one or more of, without
limitation, a vibration sensor, a thermometer, a hygrometer, a
voltage sensor and/or a current sensor (for the component and/or
other sensors measuring the component), an accelerometer, a
velocity detector, a light or electromagnetic sensor (e.g.,
determining temperature, composition, and/or spectral analysis,
and/or object position or movement), an image sensor, a structured
light sensor, a laser-based image sensor, a thermal imager, an
acoustic wave sensor, a displacement sensor, a turbidity meter, a
viscosity meter, an axial load sensor, a radial load sensor, a
tri-axial sensor, an accelerometer, a speedometer, a tachometer, a
fluid pressure meter, an air flow meter, a horsepower meter, a flow
rate meter, a fluid particle detector, an optical (laser) particle
counter, an ultrasonic sensor, an acoustical sensor, a heat flux
sensor, a galvanic sensor, a magnetometer, a pH sensor, and the
like, including, without limitation, any of the sensors described
throughout this disclosure and the documents incorporated by
reference.
[0627] The sensors 8106 may provide a stream of data over time that
has a phase component, such as relating to acceleration or
vibration, allowing for the evaluation of phase or frequency
analysis of different operational aspects of a piece of equipment
or an operating component. The sensors 8106 may provide a stream of
data that is not conventionally phase-based, such as temperature,
humidity, load, and the like. The sensors 8106 may provide a
continuous or near continuous stream of data over time, periodic
readings, event-driven readings, and/or readings according to a
selected interval or schedule.
[0628] The sensors 8106 may monitor components such as bearings,
sets of bearings, motors, driveshafts, pistons, pumps, conveyors,
vibrating conveyors, compressors, drills, and the like in vehicles,
oil and gas equipment in the field, in assembly line components,
and the like.
[0629] In embodiments, as illustrated in FIG. 51, the sensors 8106
may be part of the data monitoring device 8100, referred to herein
in some cases as a data collector, which in some cases may comprise
a mobile or portable data collector. In embodiments, as illustrated
in FIGS. 52 and 53, one or more external sensors 8126, which are
not explicitly part of a monitoring device 8120 but rather are new,
previously attached to or integrated into the equipment or
component, may be opportunistically connected to, or accessed by
the monitoring device 8120. The monitoring device 8120 may include
a controller 8122. The controller 8122 may include a data
acquisition circuit 8104, a data analysis circuit 8108, a MUX
control circuit 8114, and a response circuit 8110. The data
acquisition circuit 8104 may comprise a MUX 8112 where the inputs
correspond to a subset of the detection values. The MUX control
circuit 8114 may be structured to provide the logical control of
the MUX and the correspondence of MUX input and detected values
based on a subset of the plurality of detection values and/or a
command from the response circuit 8110 and/or the output of the
data analysis circuit 8108. The data analysis circuit 8108 may
comprise one or more of a peak detection circuit, a phase
differential circuit, a PLL circuit, a bandpass filter circuit, a
frequency transformation circuit, a frequency analysis circuit, a
torsional analysis circuit, a bearing analysis circuit, an overload
detection circuit, vibrational resonance circuit for the
identification of unfavorable interaction among machines or
components, a distortion identification circuit for the
identification of unfavorable distortions such as deflections
shapes upon operation, stress and strain-based effects, and the
like.
[0630] The one or more external sensors 8126 may be directly
connected to the one or more input ports 8128 on the data
acquisition circuit 8104 of the controller 8122 or may be accessed
by the data acquisition circuit 8104 wirelessly, such as by a
reader, interrogator, or other wireless connection, such as over a
short-distance wireless protocol. In embodiments, as shown in FIG.
53, a data acquisition circuit 8104 may further comprise a wireless
communication circuit 8130. The data acquisition circuit 8104 may
use the wireless communication circuit 8130 to access detection
values corresponding to the one or more external sensors 8126
wirelessly or via a separate source or some combination of these
methods.
[0631] In embodiments, as illustrated in FIG. 54, the controller
8134 may further comprise a data storage circuit 8136. The data
storage circuit 8136 may be structured to store one or more of
sensor specifications, component specifications, anticipated state
information, detected values, multiplexer output, component models,
and the like. The data storage circuit 8136 may provide
specifications and anticipated state information to the data
analysis circuit 8108.
[0632] In embodiments, the response circuit 8110 may initiate a
variety of actions based on the sensor status provided by the data
analysis circuit 8108. The response circuit 8110 may adjust a
sensor scaling value (e.g., from 100 mV/gram to 10 mV/gram). The
response circuit 8110 may select an alternate sensor from a
plurality available. The response circuit 8110 may acquire data
from a plurality of sensors of different ranges. The response
circuit 8110 may recommend an alternate sensor. The response
circuit 8110 may issue an alarm or an alert.
[0633] In embodiments, the response circuit 8110 may cause the data
acquisition circuit 8104 to enable or disable the processing of
detection values corresponding to certain sensors based on the
component status. This may include switching to sensors having
different response rates, sensitivity, ranges, and the like;
accessing new sensors or types of sensors, accessing data from
multiple sensors, and the like. Switching may be undertaken based
on a model, a set of rules, or the like. In embodiments, switching
may be under control of a machine learning system, such that
switching is controlled based on one or more metrics of success,
combined with input data, over a set of trials, which may occur
under supervision of a human supervisor or under control of an
automated system. Switching may involve switching from one input
port to another (such as to switch from one sensor to another).
Switching may involve altering the multiplexing of data, such as
combining different streams under different circumstances.
Switching may involve activating a system to obtain additional
data, such as moving a mobile system (such as a robotic or drone
system), to a location where different or additional data is
available, such as positioning an image sensor for a different view
or positioning a sonar sensor for a different direction of
collection, or to a location where different sensors can be
accessed, such as moving a collector to connect up to a sensor at a
location in an environment by a wired or wireless connection. This
switching may be implemented by directing changes to the
multiplexer (MUX) control circuit 8114.
[0634] In embodiments, the response circuit 8110 may make
recommendations for the replacement of certain sensors in the
future with sensors having different response rates, sensitivity,
ranges, and the like. The response circuit 8110 may recommend
design alterations for future embodiments of the component, the
piece of equipment, the operating conditions, the process, and the
like.
[0635] In embodiments, the response circuit 8110 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call where the maintenance may include the replacement of the
sensor with the same or an alternate type of sensor having a
different response rate, sensitivity, range, and the like. In
embodiments, the response circuit 8110 may implement or recommend
process changes--for example to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but is still at least
partially operational, to change the operating speed of a component
(such as to put it in a lower-demand mode), to initiate
amelioration of an issue (such as to signal for additional
lubrication of a roller bearing set, or to signal for an alignment
process for a system that is out of balance), and the like.
[0636] In embodiments, the data analysis circuit 8108 and/or the
response circuit 8110 may periodically store certain detection
values and/or the output of the multiplexers and/or the data
corresponding to the logic control of the MUX in the data storage
circuit 8136 to enable the tracking of component performance over
time. In embodiments, based on sensor status, as described
elsewhere herein, recently measured sensor data and related
operating conditions such as RPMs, component loads, temperatures,
pressures, vibrations, or other sensor data of the types described
throughout this disclosure in the data storage circuit 8136 enable
the backing out of overloaded/failed sensor data. The signal
evaluation circuit 8108 may store data at a higher data rate for
greater granularity in future processing, the ability to reprocess
at different sampling rates, and/or to enable diagnosing or
post-processing of system information where operational data of
interest is flagged, and the like.
[0637] In embodiments, as shown in FIGS. 55, 56, 57, and 58, a data
monitoring system 8138 may include at least one data monitoring
device 8140. The at least one data monitoring device 8140 may
include sensors 8106 and a controller 8142 comprising a data
acquisition circuit 8104, a data analysis circuit 8108, a data
storage circuit 8136, and a communication circuit 8146 to allow
data and analysis to be transmitted to a monitoring application
8150 on a remote server 8148. The signal evaluation circuit 8108
may include at least an overload detection circuit (e.g., reference
FIGS. 101 and 102) and/or a sensor fault detection circuit (e.g.,
reference FIGS. 101 and 102). The signal evaluation circuit 8108
may periodically share data with the communication circuit 8146 for
transmittal to the remote server 8148 to enable the tracking of
component and equipment performance over time and under varying
conditions by a monitoring application 8150. Based on the sensor
status, the signal evaluation circuit 8108 and/or response circuit
8110 may share data with the communication circuit 8146 for
transmittal to the remote server 8148 based on the fit of data
relative to one or more criteria. Data may include recent sensor
data and additional data such as RPMs, component loads,
temperatures, pressures, vibrations, and the like for transmittal.
The signal evaluation circuit 8108 may share data at a higher data
rate for transmittal to enable greater granularity in processing on
the remote server.
[0638] In embodiments, as shown in FIG. 55, the communication
circuit 8146 may communicate data directly to a remote server 8148.
In embodiments, as shown in FIG. 56, the communication circuit 8146
may communicate data to an intermediate computer 8152 which may
include a processor 8154 running an operating system 8156 and a
data storage circuit 8158.
[0639] In embodiments as illustrated in FIGS. 57 and 58, a data
collection system 8160 may have a plurality of monitoring devices
8144 collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment, (both the same and different types of
equipment) in the same facility, as well as collecting data from
monitoring devices in multiple facilities. A monitoring application
8150 on a remote server 8148 may receive and store one or more of
detection values, timing signals, and data coming from a plurality
of the various monitoring devices 8144.
[0640] In embodiments, as shown in FIG. 57, the communication
circuit 8146 may communicate data directly to a remote server 8148.
In embodiments, as shown in FIG. 58, the communication circuit 8146
may communicate data to an intermediate computer 8152 which may
include a processor 8154 running an operating system 8156 and a
data storage circuit 8158. There may be an individual intermediate
computer 8152 associated with each monitoring device 8140 or an
individual intermediate computer 8152 may be associated with a
plurality of monitoring devices 8144 where the intermediate
computer 8152 may collect data from a plurality of data monitoring
devices and send the cumulative data to the remote server 8148.
Communication to the remote server 8148 may be streaming, batch
(e.g., when a connection is available), or opportunistic.
[0641] The monitoring application 8150 may select subsets of the
detection values to be jointly analyzed. Subsets for analysis may
be selected based on a single type of sensor, component, or a
single type of equipment in which a component is operating. Subsets
for analysis may be selected or grouped based on common operating
conditions such as size of load, operational condition (e.g.,
intermittent or continuous), operating speed or tachometer output,
common ambient environmental conditions such as humidity,
temperature, air or fluid particulate, and the like. Subsets for
analysis may be selected based on the effects of other nearby
equipment such as nearby machines rotating at similar frequencies,
nearby equipment producing electromagnetic fields, nearby equipment
producing heat, nearby equipment inducing movement or vibration,
nearby equipment emitting vapors, chemicals or particulates, or
other potentially interfering or intervening effects.
[0642] In embodiments, the monitoring application 8150 may analyze
the selected subset. In an example, data from a single sensor may
be analyzed over different time periods such as one operating
cycle, several operating cycles, a month, a year, the life of the
component, or the like. Data from multiple sensors of a common type
measuring a common component type may also be analyzed over
different time periods. Trends in the data such as changing rates
of change associated with start-up or different points in the
process may be identified. Correlation of trends and values for
different sensors may be analyzed to identify those parameters
whose short-term analysis might provide the best prediction
regarding expected sensor performance. This information may be
transmitted back to the monitoring device to update sensor models,
sensor selection, sensor range, sensor scaling, sensor sampling
frequency, types of data collected, and the like, and be analyzed
locally or to influence the design of future monitoring
devices.
[0643] In embodiments, the monitoring application 8150 may have
access to equipment specifications, equipment geometry, component
specifications, component materials, anticipated state information
for a plurality of sensors, operational history, historical
detection values, sensor life models, and the like for use
analyzing the selected subset using rule-based or model-based
analysis. The monitoring application 8150 may provide
recommendations regarding sensor selection, additional data to
collect, data to store with sensor data, and the like. The
monitoring application 8150 may provide recommendations regarding
scheduling repairs and/or maintenance. The monitoring application
8150 may provide recommendations regarding replacing a sensor. The
replacement sensor may match the sensor being replaced or the
replacement sensor may have a different range, sensitivity,
sampling frequency, and the like.
[0644] In embodiments, the monitoring application 8150 may include
a remote learning circuit structured to analyze sensor status data
(e.g., sensor overload or sensor failure) together with data from
other sensors, failure data on components being monitored,
equipment being monitored, output being produced, and the like. The
remote learning system may identify correlations between sensor
overload and data from other sensors.
[0645] An example monitoring system for data collection in an
industrial environment includes a data acquisition circuit that
interprets a number of detection values, each of the detection
values corresponding to input received from at least one of a
number of input sensors, a MUX having inputs corresponding to a
subset of the detection values, a MUX control circuit that
interprets a subset of the number of detection values and provides
the logical control of the MUX and the correspondence of MUX input
and detected values as a result, where the logic control of the MUX
includes adaptive scheduling of the select lines, a data analysis
circuit that receives an output from the MUX and data corresponding
to the logic control of the MUX resulting in a component health
status, an analysis response circuit that performs an operation in
response to the component health status, where the number of
sensors includes at least two sensors such as a temperature sensor,
a load sensor, a vibration sensor, an acoustic wave sensor, a heat
flux sensor, an infrared sensor, an accelerometer, a tri-axial
vibration sensor, and/or a tachometer. In certain further
embodiments, an example system includes: where at least one of the
number of detection values may correspond to a fusion of two or
more input sensors representing a virtual sensor; where the system
further includes a data storage circuit that stores at least one of
component specifications and anticipated component state
information and buffers a subset of the number of detection values
for a predetermined length of time; where the system further
includes a data storage circuit that stores at least one of a
component specification and anticipated component state information
and buffers the output of the MUX and data corresponding to the
logic control of the MUX for a predetermined length of time; where
the data analysis circuit includes a peak detection circuit, a
phase detection circuit, a bandpass filter circuit, a frequency
transformation circuit, a frequency analysis circuit, a PLL
circuit, a torsional analysis circuit, and/or a bearing analysis
circuit; where operation further includes storing additional data
in the data storage circuit; where the operation includes at least
one of enabling or disabling one or more portions of the MUX
circuit; and/or where the operation includes causing the MUX
control circuit to alter the logical control of the MUX and the
correspondence of MUX input and detected values. In certain
embodiments, the system includes at least two multiplexers; control
of the correspondence of the multiplexer input and the detected
values further includes controlling the connection of the output of
a first multiplexer to an input of a second multiplexer; control of
the correspondence of the multiplexer input and the detected values
further comprises powering down at least a portion of one of the at
least two multiplexers; and/or control of the correspondence of MUX
input and detected values includes adaptive scheduling of the
select lines. In certain embodiments, a data response circuit
analyzes the stream of data from one or both MUXes, and recommends
an action in response to the analysis.
[0646] An example testing system includes the testing system in
communication with a number of analog and digital input sensors, a
monitoring device including a data acquisition circuit that
interprets a number of detection values, each of the number of
detection values corresponding to at least one of the input
sensors, a MUX having inputs corresponding to a subset of the
detection values, a MUX control circuit that interprets a subset of
the number of detection values and provides the logical control of
the MUX and control of the correspondence of MUX input and detected
values as a result, where the logic control of the MUX includes
adaptive scheduling of the select lines, and a user interface
enabled to accept scheduling input for select lines and display
output of MUX and select line data.
[0647] In embodiments, information about the health or other status
or state information of or regarding a component or piece of
industrial equipment may be obtained by looking at both the
amplitude and phase or timing of data signals relative to related
data signals, timers, reference signals or data measurements. An
embodiment of a data monitoring device 8500 is shown in FIG. 59 and
may include a plurality of sensors 8506 communicatively coupled to
a controller 8502. The controller 8502 may include a data
acquisition circuit 8504, a signal evaluation circuit 8508 and a
response circuit 8510. The plurality of sensors 8506 may be wired
to ports on the data acquisition circuit 8504 or wirelessly in
communication with the data acquisition circuit 8504. The plurality
of sensors 8506 may be wirelessly connected to the data acquisition
circuit 8504. The data acquisition circuit 8504 may be able to
access detection values corresponding to the output of at least one
of the plurality of sensors 8506 where the sensors 8506 may be
capturing data on different operational aspects of a piece of
equipment or an operating component.
[0648] The selection of the plurality of sensors 8506 for a data
monitoring device 8500 designed for a specific component or piece
of equipment may depend on a variety of considerations such as
accessibility for installing new sensors, incorporation of sensors
in the initial design, anticipated operational and failure
conditions, reliability of the sensors, and the like. The impact of
failure may drive the extent to which a component or piece of
equipment is monitored with more sensors and/or higher capability
sensors being dedicated to systems where unexpected or undetected
failure would be costly or have severe consequences.
[0649] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating and
the like, sensors 8506 may comprise one or more of, without
limitation, a vibration sensor, a thermometer, a hygrometer, a
voltage sensor, a current sensor, an accelerometer, a velocity
detector, a light or electromagnetic sensor (e.g., determining
temperature, composition and/or spectral analysis, and/or object
position or movement), an image sensor, a structured light sensor,
a laser-based image sensor, an acoustic wave sensor, a displacement
sensor, a turbidity meter, a viscosity meter, a load sensor, a
tri-axial sensor, an accelerometer, a tachometer, a fluid pressure
meter, an air flow meter, a horsepower meter, a flow rate meter, a
fluid particle detector, an acoustical sensor, a pH sensor, and the
like, including, without limitation, any of the sensors described
throughout this disclosure and the documents incorporated by
reference.
[0650] The sensors 8506 may provide a stream of data over time that
has a phase component, such as relating to acceleration or
vibration, allowing for the evaluation of phase or frequency
analysis of different operational aspects of a piece of equipment
or an operating component. The sensors 8506 may provide a stream of
data that is not conventionally phase-based, such as temperature,
humidity, load, and the like. The sensors 8506 may provide a
continuous or near continuous stream of data over time, periodic
readings, event-driven readings, and/or readings according to a
selected interval or schedule.
[0651] In embodiments, as illustrated in FIG. 59, the sensors 8506
may be part of the data monitoring device 8500, referred to herein
in some cases as a data collector, which in some cases may comprise
a mobile or portable data collector. In embodiments, as illustrated
in FIGS. 60 and 61, sensors 8518, either new or previously attached
to or integrated into the equipment or component, may be
opportunistically connected to or accessed by a monitoring device
8512. The sensors 8518 may be directly connected to input ports
8520 on the data acquisition circuit 8516 of a controller 8514 or
may be accessed by the data acquisition circuit 8516 wirelessly,
such as by a reader, interrogator, or other wireless connection,
such as over a short-distance wireless protocol. In embodiments, a
data acquisition circuit 8516 may access detection values
corresponding to the sensors 8518 wirelessly or via a separate
source or some combination of these methods. In embodiments, the
data acquisition circuit 8504 may include a wireless communications
circuit 8522 able to wirelessly receive data opportunistically from
sensors 8518 in the vicinity and route the data to the input ports
8520 on the data acquisition circuit 8516.
[0652] In an embodiment, as illustrated in FIGS. 62 and 63, the
signal evaluation circuit 8508 may then process the detection
values to obtain information about the component or piece of
equipment being monitored. Information extracted by the signal
evaluation circuit 8508 may comprise rotational speed, vibrational
data including amplitudes, frequencies, phase, and/or acoustical
data, and/or non-phase sensor data such as temperature, humidity,
image data, and the like.
[0653] The signal evaluation circuit 8508 may include one or more
components such as a phase detection circuit 8528 to determine a
phase difference between two time-based signals, a phase lock loop
circuit 8530 to adjust the relative phase of a signal such that it
is aligned with a second signal, timer or reference signal, and/or
a band pass filter circuit 8532 which may be used to separate out
signals occurring at different frequencies. An example band pass
filter circuit 8532 includes any filtering operations understood in
the art, including at least a low-pass filter, a high-pass filter,
and/or a band pass filter--for example to exclude or reduce
frequencies that are not of interest for a particular
determination, and/or to enhance the signal for frequencies of
interest. Additionally, or alternatively, a band pass filter
circuit 8532 includes one or more notch filters or other filtering
mechanism to narrow ranges of frequencies (e.g., frequencies from a
known source of noise). This may be used to filter out dominant
frequency signals such as the overall rotation, and may help enable
the evaluation of low amplitude signals at frequencies associated
with torsion, bearing failure and the like.
[0654] In embodiments, understanding the relative differences may
be enabled by a phase detection circuit 8528 to determine a phase
difference between two signals. It may be of value to understand a
relative phase offset, if any, between signals such as when a
periodic vibration occurs relative to a relative rotation of a
piece of equipment. In embodiments, there may be value in
understanding where in a cycle shaft vibrations occur relative to a
motor control input to better balance the control of the motor.
This may be particularly true for systems and components that are
operating at relative slow RPMs. Understanding of the phase
difference between two signals or between those signals and a timer
may enable establishing a relationship between a signal value and
where it occurs in a process or rotation. Understanding relative
phase differences may help in evaluating the relationship between
different components of a system such as in the creation of a
vibrational model for an Operational Deflection Shape (ODS).
[0655] The signal evaluation circuit 8544 may perform frequency
analysis using techniques such as a digital Fast Fourier transform
(FFT), Laplace transform, Z-transform, wavelet transform, other
frequency domain transform, or other digital or analog signal
analysis techniques, including, without limitation, complex
analysis, including complex phase evolution analysis. An overall
rotational speed or tachometer may be derived from data from
sensors such as rotational velocity meters, accelerometers,
displacement meters and the like. Additional frequencies of
interest may also be identified. These may include frequencies near
the overall rotational speed as well as frequencies higher than
that of the rotational speed. These may include frequencies that
are nonsynchronous with an overall rotational speed. Signals
observed at frequencies that are multiples of the rotational speed
may be due to bearing induced vibrations or other behaviors or
situations involving bearings. In some instances, these frequencies
may be in the range of one times the rotational speed, two times
the rotational speed, three times the rotational speed, and the
like, up to 3.15 to 15 times the rotational speed, or higher. In
some embodiments, the signal evaluation circuit 8544 may select RC
components for a band pass filter circuit 8532 based on overall
rotational speed to create a band pass filter circuit 8532 to
remove signals at expected frequencies such as the overall
rotational speed, to facilitate identification of small amplitude
signals at other frequencies. In embodiments, variable components
may be selected, such that adjustments may be made in keeping with
changes in the rotational speed, so that the band pass filter may
be a variable band pass filter. This may occur under control of
automatically self-adjusting circuit elements, or under control of
a processor, including automated control based on a model of the
circuit behavior, where a rotational speed indicator or other data
is provided as a basis for control.
[0656] In embodiments, rather than performing frequency analysis,
the signal evaluation circuit 8544 may utilize the time-based
detection values to perform transitory signal analysis. These may
include identifying abrupt changes in signal amplitude including
changes where the change in amplitude exceeds a predetermined value
or exists for a certain duration. In embodiments, the time-based
sensor data may be aligned with a timer or reference signal
allowing the time-based sensor data to be aligned with, for
example, a time or location in a cycle. Additional processing to
look at frequency changes over time may include the use of
Short-Time Fourier Transforms (STFT) or a wavelet transform.
[0657] In embodiments, frequency-based techniques and time-based
techniques may be combined, such as using time-based techniques to
determine discrete time periods during which given operational
modes or states are occurring and using frequency-based techniques
to determine behavior within one or more of the discrete time
periods.
[0658] In embodiments, the signal evaluation circuit may utilize
demodulation techniques for signals obtained from equipment running
at slow speeds such as paper and pulp machines, mining equipment,
and the like. A signal evaluation circuit employing a demodulation
technique may comprise a band-pass filter circuit, a rectifier
circuit, and/or a low pass circuit prior to transforming the data
to the frequency domain.
[0659] The response circuit 8510 8710 may further comprise
evaluating the results of the signal evaluation circuit 8508 8544
and, based on certain criteria, initiating an action. Criteria may
include a predetermined maximum or minimum value for a detection
value from a specific sensor, a value of a sensor's corresponding
detection value over time, a change in value, a rate of change in
value, and/or an accumulated value (e.g., a time spent above/below
a threshold value, a weighted time spent above/below one or more
threshold values, and/or an area of the detected value above/below
one or more threshold values). The criteria may include a sensor's
detection values at certain frequencies or phases where the
frequencies or phases may be based on the equipment geometry,
equipment control schemes, system input, historical data, current
operating conditions, and/or an anticipated response. The criteria
may comprise combinations of data from different sensors such as
relative values, relative changes in value, relative rates of
change in value, relative values over time, and the like. The
relative criteria may change with other data or information such as
process stage, type of product being processed, type of equipment,
ambient temperature and humidity, external vibrations from other
equipment, and the like. The relative criteria may include level of
synchronicity with an overall rotational speed, such as to
differentiate between vibration induced by bearings and vibrations
resulting from the equipment design. In embodiments, the criteria
may be reflected in one or more calculated statistics or metrics
(including ones generated by further calculations on multiple
criteria or statistics), which in turn may be used for processing
(such as on board a data collector or by an external system), such
as to be provided as an input to one or more of the machine
learning capabilities described in this disclosure, to a control
system (which may be an on-board data collector or remote, such as
to control selection of data inputs, multiplexing of sensor data,
storage, or the like), or as a data element that is an input to
another system, such as a data stream or data package that may be
available to a data marketplace, a SCADA system, a remote control
system, a maintenance system, an analytic system, or other
system.
[0660] In an illustrative and non-limiting example, an alert may be
issued if the vibrational amplitude and/or frequency exceeds a
predetermined maximum value, if there is a change or rate of change
that exceeds a predetermined acceptable range, and/or if an
accumulated value based on vibrational amplitude and/or frequency
exceeds a threshold. Certain embodiments are described herein as
detected values exceeding thresholds or predetermined values, but
detected values may also fall below thresholds or predetermined
values--for example where an amount of change in the detected value
is expected to occur, but detected values indicate that the change
may not have occurred. For example, and without limitation,
vibrational data may indicate system agitation levels, properly
operating equipment, or the like, and vibrational data below
amplitude and/or frequency thresholds may be an indication of a
process that is not operating according to expectations. Except
where the context clearly indicates otherwise, any description
herein describing a determination of a value above a threshold
and/or exceeding a predetermined or expected value is understood to
include determination of a value below a threshold and/or falling
below a predetermined or expected value.
[0661] The predetermined acceptable range may be based on
anticipated system response or vibration based on the equipment
geometry and control scheme such as number of bearings, relative
rotational speed, influx of power to the system at a certain
frequency, and the like. The predetermined acceptable range may
also be based on long term analysis of detection values across a
plurality of similar equipment and components and correlation of
data with equipment failure. Based on vibration phase information,
a physical location of a problem may be identified. Based on the
vibration phase information system design flaws, off-nominal
operation, and/or component or process failures may be identified.
In some embodiments, an alert may be issued based on changes or
rates of change in the data over time such as increasing amplitude
or shifts in the frequencies or phases at which a vibration occurs.
In some embodiments, an alert may be issued based on accumulated
values such as time spent over a threshold, weighted time spent
over one or more thresholds, and/or an area of a curve of the
detected value over one or more thresholds. In embodiments, an
alert may be issued based on a combination of data from different
sensors such as relative changes in value, or relative rates of
change in amplitude, frequency of phase in addition to values of
non-phase sensors such as temperature, humidity and the like. For
example, an increase in temperature and energy at certain
frequencies may indicate a hot bearing that is starting to fail. In
embodiments, the relative criteria for an alarm may change with
other data or information such as process stage, type of product
being processed on equipment, ambient temperature and humidity,
external vibrations from other equipment and the like.
[0662] In embodiments, response circuit 8510 may cause the data
acquisition circuit 8504 to enable or disable the processing of
detection values corresponding to certain sensors based on the some
of the criteria discussed above. This may include switching to
sensors having different response rates, sensitivity, ranges, and
the like; accessing new sensors or types of sensors, and the like.
Switching may be undertaken based on a model, a set of rules, or
the like. In embodiments, switching may be under control of a
machine learning system, such that switching is controlled based on
one or more metrics of success, combined with input data, over a
set of trials, which may occur under supervision of a human
supervisor or under control of an automated system. Switching may
involve switching from one input port to another (such as to switch
from one sensor to another). Switching may involve altering the
multiplexing of data, such as combining different streams under
different circumstances. Switching may involve activating a system
to obtain additional data, such as moving a mobile system (such as
a robotic or drone system), to a location where different or
additional data is available (such as positioning an image sensor
for a different view or positioning a sonar sensor for a different
direction of collection) or to a location where different sensors
can be accessed (such as moving a collector to connect up to a
sensor that is disposed at a location in an environment by a wired
or wireless connection). The response circuit 8510 may make
recommendations for the replacement of certain sensors in the
future with sensors having different response rates, sensitivity,
ranges, and the like. The response circuit 8510 may recommend
design alterations for future embodiments of the component, the
piece of equipment, the operating conditions, the process, and the
like.
[0663] In embodiments, the response circuit 8510 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call. The response circuit 8510 may recommend changes in process or
operating parameters to remotely balance the piece of equipment. In
embodiments, the response circuit 8510 may implement or recommend
process changes--for example to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but still at least partially
operational, to change the operating speed of a component (such as
to put it in a lower-demand mode), to initiate amelioration of an
issue (such as to signal for additional lubrication of a roller
bearing set, or to signal for an alignment process for a system
that is out of balance), and the like.
[0664] In embodiments, as shown in FIG. 64, the data monitoring
device 8540 may further comprise a data storage circuit 8542,
memory, and the like. The signal evaluation circuit 8544 may
periodically store certain detection values to enable the tracking
of component performance over time.
[0665] In embodiments, based on relevant operating conditions
and/or failure modes which may occur in as sensor values approach
one or more criteria, the signal evaluation circuit 8544 may store
data in the data storage circuit 8542 based on the fit of data
relative to one or more criteria, such as those described
throughout this disclosure. Based on one sensor input meeting or
approaching specified criteria or range, the signal evaluation
circuit 8544 may store additional data such as RPMs, component
loads, temperatures, pressures, vibrations or other sensor data of
the types described throughout this disclosure. The signal
evaluation circuit 8544 may store data at a higher data rate for
greater granularity in future processing, the ability to reprocess
at different sampling rates, and/or to enable diagnosing or
post-processing of system information where operational data of
interest is flagged, and the like.
[0666] In embodiments, as shown in FIG. 65, a data monitoring
system 8546 may comprise at least one data monitoring device 8548.
The at least one data monitoring device 8548 comprising sensors
8506, a controller 8550 comprising a data acquisition circuit 8504,
a signal evaluation circuit 8538, a data storage circuit 8542, and
a communications circuit 8552 to allow data and analysis to be
transmitted to a monitoring application 8556 on a remote server
8554. The signal evaluation circuit 8538 may comprise at least one
of a phase detection circuit 8528, a phase lock loop circuit 8530,
and/or a band pass circuit 8532. The signal evaluation circuit 8538
may periodically share data with the communication circuit 8552 for
transmittal to the remote server 8554 to enable the tracking of
component and equipment performance over time and under varying
conditions by a monitoring application 8556. Because relevant
operating conditions and/or failure modes may occur as sensor
values approach one or more criteria, the signal evaluation circuit
8538 may share data with the communication circuit 8552 for
transmittal to the remote server 8554 based on the fit of data
relative to one or more criteria. Based on one sensor input meeting
or approaching specified criteria or range, the signal evaluation
circuit 8538 may share additional data such as RPMs, component
loads, temperatures, pressures, vibrations, and the like for
transmittal. The signal evaluation circuit 8538 may share data at a
higher data rate for transmittal to enable greater granularity in
processing on the remote server.
[0667] In embodiments, as illustrated in FIG. 66, a data collection
system 8560 may have a plurality of monitoring devices 8558
collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment (both the same and different types of
equipment) in the same facility, as well as collecting data from
monitoring devices in multiple facilities. A monitoring application
on a remote server may receive and store the data coming from a
plurality of the various monitoring devices. The monitoring
application may then select subsets of data which may be jointly
analyzed. Subsets of monitoring data may be selected based on data
from a single type of component or data from a single type of
equipment in which the component is operating. Monitoring data may
be selected or grouped based on common operating conditions such as
size of load, operational condition (e.g., intermittent,
continuous), operating speed or tachometer, common ambient
environmental conditions such as humidity, temperature, air or
fluid particulate, and the like. Monitoring data may be selected
based on the effects of other nearby equipment, such as nearby
machines rotating at similar frequencies, nearby equipment
producing electromagnetic fields, nearby equipment producing heat,
nearby equipment inducing movement or vibration, nearby equipment
emitting vapors, chemicals or particulates, or other potentially
interfering or intervening effects.
[0668] The monitoring application may then analyze the selected
data set. For example, data from a single component may be analyzed
over different time periods such as one operating cycle, several
operating cycles, a month, a year, or the like. Data from multiple
components of the same type may also be analyzed over different
time periods. Trends in the data such as changes in frequency or
amplitude may be correlated with failure and maintenance records
associated with the same component or piece of equipment. Trends in
the data such as changing rates of change associated with start-up
or different points in the process may be identified. Additional
data may be introduced into the analysis such as output product
quality, output quantity (such as per unit of time), indicated
success or failure of a process, and the like. Correlation of
trends and values for different types of data may be analyzed to
identify those parameters whose short-term analysis might provide
the best prediction regarding expected performance. This
information may be transmitted back to the monitoring device to
update types of data collected and analyzed locally or to influence
the design of future monitoring devices.
[0669] In an illustrative and non-limiting example, the monitoring
device may be used to collect and process sensor data to measure
mechanical torque. The monitoring device may be in communication
with or include a high resolution, high speed vibration sensor to
collect data over an extended period of time, enough to measure
multiple cycles of rotation. For gear driven equipment, the
sampling resolution should be such that the number of samples taken
per cycle is at least equal to the number of gear teeth driving the
component. It will be understood that a lower sampling resolution
may also be utilized, which may result in a lower confidence
determination and/or taking data over a longer period of time to
develop sufficient statistical confidence. This data may then be
used in the generation of a phase reference (relative probe) or
tachometer signal for a piece of equipment. This phase reference
may be used to align phase data such as vibrational data or
acceleration data from multiple sensors located at different
positions on a component or on different components within a
system. This information may facilitate the determination of torque
for different components or the generation of an Operational
Deflection Shape (ODS), indicating the extent of mechanical
deflection of one or more components during an operational mode,
which in turn may be used to measure mechanical torque in the
component.
[0670] The higher resolution data stream may provide additional
data for the detection of transitory signals in low speed
operations. The identification of transitory signals may enable the
identification of defects in a piece of equipment or component
[0671] In an illustrative and non-limiting example, the monitoring
device may be used to identify mechanical jitter for use in failure
prediction models. The monitoring device may begin acquiring data
when the piece of equipment starts up through ramping up to
operating speed and then during operation. Once at operating speed,
it is anticipated that the torsional jitter should be minimal and
changes in torsion during this phase may be indicative of cracks,
bearing faults and the like. Additionally, known torsions may be
removed from the signal to facilitate in the identification of
unanticipated torsions resulting from system design flaws or
component wear. Having phase information associated with the data
collected at operating speed may facilitate identification of a
location of vibration and potential component wear. Relative phase
information for a plurality of sensors located throughout a machine
may facilitate the evaluation of torsion as it is propagated
through a piece of equipment.
[0672] An example system data collection in an industrial
environment includes a data acquisition circuit that interprets a
number of detection values from a number of input sensors
communicatively coupled to the data acquisition circuit, each of
the number of detection values corresponding to at least one of the
input sensors, a signal evaluation circuit that obtains at least
one of a vibration amplitude, a vibration frequency and a vibration
phase location corresponding to at least one of the input sensors
in response to the number of detection values, and a response
circuit that performs at least one operation in response to at the
at least one of the vibration amplitude, the vibration frequency
and the vibration phase location. Certain further embodiments of an
example system include: where the signal evaluation circuit
includes a phase detection circuit, or a phase detection circuit
and a phase lock loop circuit and/or a band pass filter; where the
number of input sensors includes at least two input sensors
providing phase information and at least one input sensor providing
non-phase sensor information; the signal evaluation circuit further
aligning the phase information provided by the at least two of the
input sensors; where the at least one operation is further in
response to at least one of: a change in magnitude of the vibration
amplitude; a change in frequency or phase of vibration; a rate of
change in at least one of vibration amplitude, vibration frequency
and vibration phase; a relative change in value between at least
two of vibration amplitude, vibration frequency and vibration
phase; and/or a relative rate of change between at least two of
vibration amplitude, vibration frequency, and vibration phase; the
system further including an alert circuit, where the at least one
operation includes providing an alert and where the alert may be
one of haptic, audible and visual; a data storage circuit, where at
least one of the vibration amplitude, vibration frequency, and
vibration phase is stored periodically to create a vibration
history, and where the at least one operation includes storing
additional data in the data storage circuit (e.g., as a vibration
fingerprint for a component); where the storing additional data in
the data storage circuit is further in response to at least one of:
a change in magnitude of the vibration amplitude; a change in
frequency or phase of vibration; a rate of change in the vibration
amplitude, frequency or phase; a relative change in value between
at least two of vibration amplitude, frequency and phase; and a
relative rate of change between at least two of vibration
amplitude, frequency and phase; the system further comprising at
least one of a multiplexing (MUX) circuit whereby alternative
combinations of detection values may be selected based on at least
one of user input, a detected state, and a selected operating
parameter for a machine; where each of the number of detection
values corresponds to at least one of the input sensors; where the
at least one operation includes enabling or disabling the
connection of one or more portions of the multiplexing circuit; a
MUX control circuit that interprets a subset of the number of
detection values and provides the logical control of the MUX and
the correspondence of MUX input and detected values as a result;
and/or where the logic control of the MUX includes adaptive
scheduling of the select lines.
[0673] An example method of monitoring a component, includes
receiving time-based data from at least one sensor, phase-locking
the received data with a reference signal, transforming the
received time-based data to frequency data, filtering the frequency
data to remove tachometer frequencies, identifying low amplitude
signals occurring at high frequencies, and activating an alarm if a
low amplitude signal exceeds a threshold.
[0674] An example system for data collection, processing, and
utilization of signals in an industrial environment includes a
plurality of monitoring devices, each monitoring device comprising
a data acquisition circuit structured to interpret a plurality of
detection values from a plurality of input sensors communicatively
coupled to the data acquisition circuit, each of the plurality of
detection values corresponding to at least one of the input
sensors; a signal evaluation circuit structured to obtain at least
one of vibration amplitude, vibration frequency and a vibration
phase location corresponding to at least one of the input sensors
in response to the corresponding at least one of the plurality of
detection values; a data storage facility for storing a subset of
the plurality of detection values; a communication circuit
structured to communicate at least one selected detection value to
a remote server; and a monitoring application on the remote server
structured to: receive the at least one selected detection value;
jointly analyze a subset of the detection values received from the
plurality of monitoring devices; and recommend an action.
[0675] In certain further embodiments, an example system includes:
for each monitoring device, the plurality of input sensors include
at least one input sensor providing phase information and at least
one input sensor providing non-phase input sensor information and
where joint analysis includes using the phase information from the
plurality of monitoring devices to align the information from the
plurality of monitoring devices; where the subset of detection
values is selected based on data associated with a detection value
including at least one: common type of component, common type of
equipment, and common operating conditions and further selected
based on one of anticipated life of a component associated with
detection values, type of the equipment associated with detection
values, and operational conditions under which detection values
were measured; and/or where the analysis of the subset of detection
values includes feeding a neural net with the subset of detection
values and supplemental information to learn to recognize various
operating states, health states, life expectancies and fault states
utilizing deep learning techniques, wherein the supplemental
information comprises one of component specification, component
performance, equipment specification, equipment performance,
maintenance records, repair records and an anticipated state
model.
[0676] An example system for data collection in an industrial
environment includes a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a signal evaluation circuit structured to
obtain at least one of vibration amplitude, vibration frequency and
vibration phase location corresponding to at least one of the input
sensors in response to the corresponding at least one of a
plurality of detection values; a multiplexing circuit whereby
alternative combinations of the detection values may be selected
based on at least one of user input, a detected state and a
selected operating parameter for a machine, each of the plurality
of detection values corresponding to at least one of the input
sensors; and a response circuit structured to perform at least one
operation in response to at the at least one of the vibration
amplitude, vibration frequency and vibration phase location.
[0677] An example system for data collection in a piece of
equipment, includes a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a timer circuit structured to generate a
timing signal based on a first detected value of the plurality of
detection values; a signal evaluation circuit structured to obtain
at least one of vibration amplitude, vibration frequency and
vibration phase location corresponding to a second detected value
comprising: a phase detection circuit structured to determine a
relative phase difference between a second detection value of the
plurality of detection values and the timing signal; and a response
circuit structured to perform at least one operation in response to
at the at least one of the vibration amplitude, vibration frequency
and vibration phase location.
[0678] An example system for bearing analysis in an industrial
environment, includes a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage for storing specifications
and anticipated state information for a plurality of bearing types
and buffering the plurality of detection values for a predetermined
length of time; a timer circuit structured to generate a timing
signal based on a first detected value of the plurality of
detection values; a bearing analysis circuit structured to analyze
buffered detection values relative to specifications and
anticipated state information resulting in a life prediction
comprising: a phase detection circuit structured to determine a
relative phase difference between a second detection value of the
plurality of detection values and the timing signal; and a signal
evaluation circuit structured to obtain at least one of vibration
amplitude, vibration frequency and vibration phase location
corresponding to a second detected value: and a response circuit
structured to perform at least one operation in response to at the
at least one of the vibration amplitude, vibration frequency and
vibration phase location.
[0679] An example motor monitoring system includes: a data
acquisition circuit structured to interpret a plurality of
detection values from a plurality of input sensors communicatively
coupled to the data acquisition circuit, each of the plurality of
detection values corresponding to at least one of the input
sensors; a data storage circuit structured to store specifications,
system geometry, and anticipated state information for the motor
and motor components, store historical motor performance and buffer
the plurality of detection values for a predetermined length of
time; a timer circuit structured to generate a timing signal based
on a first detected value of the plurality of detection values; a
motor analysis circuit structured to analyze buffered detection
values relative to specifications and anticipated state information
resulting in a motor performance parameter comprising: a phase
detection circuit structured to determine a relative phase
difference between a second detection value of the plurality of
detection values and the timing signal; and a signal evaluation
circuit structured to obtain at least one of vibration amplitude,
vibration frequency and vibration phase location corresponding to a
second detected value and analyze the at least one of vibration
amplitude, vibration frequency and vibration phase location
relative to buffered detection values, specifications and
anticipated state information resulting in a motor performance
parameter; and a response circuit structured to perform at least
one operation in response to at the at least one of vibration
amplitude, vibration frequency and vibration phase location and
motor performance parameter.
[0680] An example system for estimating a vehicle steering system
performance parameter, includes: a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for the vehicle steering system, the
rack, the pinion, and the steering column, store historical
steering system performance and buffer the plurality of detection
values for a predetermined length of time;
a timer circuit structured to generate a timing signal based on a
first detected value of the plurality of detection values; a
steering system analysis circuit structured to analyze buffered
detection values relative to specifications and anticipated state
information resulting in a steering system performance parameter
comprising: a phase detection circuit structured to determine a
relative phase difference between a second detection value of the
plurality of detection values and the timing signal; and a signal
evaluation circuit structured to obtain at least one of vibration
amplitude, vibration frequency and vibration phase location
corresponding to a second detected value and analyze the at least
one of vibration amplitude, vibration frequency and vibration phase
location relative to buffered detection values, specifications and
anticipated state information resulting in a steering system
performance parameter; and a response circuit structured to perform
at least one operation in response to at the at least one of
vibration amplitude, vibration frequency and vibration phase
location and the steering system performance parameter.
[0681] An example system for estimating a health parameter a pump
performance parameter includes a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for the pump and pump components
associated with the detection values, store historical pump
performance and buffer the plurality of detection values for a
predetermined length of time; a timer circuit structured to
generate a timing signal based on a first detected value of the
plurality of detection values; a pump analysis circuit structured
to analyze buffered detection values relative to specifications and
anticipated state information resulting in a pump performance
parameter comprising: a phase detection circuit structured to
determine a relative phase difference between a second detection
value of the plurality of detection values and the timing signal;
and a signal evaluation circuit structured to obtain at least one
of vibration amplitude, vibration frequency and vibration phase
location corresponding to a second detected value and analyze the
at least one of vibration amplitude, vibration frequency and
vibration phase location relative to buffered detection values,
specifications and anticipated state information resulting in a
pump performance parameter; and a response circuit structured to
perform at least one operation in response to at the at least one
of vibration amplitude, vibration frequency and vibration phase
location and the pump performance parameter, wherein the pump is
one of a water pump in a car and a mineral pump.
[0682] An example system for estimating a drill performance
parameter for a drilling machine, includes: a data acquisition
circuit structured to interpret a plurality of detection values
from a plurality of input sensors communicatively coupled to the
data acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for the drill and drill components
associated with the detection values, store historical drill
performance and buffer the plurality of detection values for a
predetermined length of time; a timer circuit structured to
generate a timing signal based on a first detected value of the
plurality of detection values; a drill analysis circuit structured
to analyze buffered detection values relative to specifications and
anticipated state information resulting in a drill performance
parameter comprising: a phase detection circuit structured to
determine a relative phase difference between a second detection
value of the plurality of detection values and the timing signal;
and a signal evaluation circuit structured to obtain at least one
of vibration amplitude, vibration frequency and vibration phase
location corresponding to a second detected value and analyze the
at least one of vibration amplitude, vibration frequency and
vibration phase location relative to buffered detection values,
specifications and anticipated state information resulting in a
drill performance parameter; and a response circuit structured to
perform at least one operation in response to at the at least one
of vibration amplitude, vibration frequency and vibration phase
location and the drill performance parameter, wherein the drilling
machine is one of an oil drilling machine and a gas drilling
machine.
[0683] An example system for estimating a conveyor health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage circuit structured to
store specifications, system geometry, and anticipated state
information for a conveyor and conveyor components associated with
the detection values, store historical conveyor performance and
buffer the plurality of detection values for a predetermined length
of time; a timer circuit structured to generate a timing signal
based on a first detected value of the plurality of detection
values; a conveyor analysis circuit structured to analyze buffered
detection values relative to specifications and anticipated state
information resulting in a conveyor performance parameter
comprising: a phase detection circuit structured to determine a
relative phase difference between a second detection value of the
plurality of detection values and the timing signal; and a signal
evaluation circuit structured to obtain at least one of vibration
amplitude, vibration frequency and vibration phase location
corresponding to a second detected value and analyze the at least
one of vibration amplitude, vibration frequency and vibration phase
location relative to buffered detection values, specifications and
anticipated state information resulting in a conveyor performance
parameter; and a response circuit structured to perform at least
one operation in response to at the at least one of vibration
amplitude, vibration frequency and vibration phase location and the
conveyor performance parameter.
[0684] An example system for estimating an agitator health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage circuit structured to
store specifications, system geometry, and anticipated state
information for an agitator and agitator components associated with
the detection values, store historical agitator performance and
buffer the plurality of detection values for a predetermined length
of time; a timer circuit structured to generate a timing signal
based on a first detected value of the plurality of detection
values; an agitator analysis circuit structured to analyze buffered
detection values relative to specifications and anticipated state
information resulting in an agitator performance parameter
comprising: a phase detection circuit structured to determine a
relative phase difference between a second detection value of the
plurality of detection values and the timing signal; and a signal
evaluation circuit structured to obtain at least one of vibration
amplitude, vibration frequency and vibration phase location
corresponding to a second detected value and analyze the at least
one of vibration amplitude, vibration frequency and vibration phase
location relative to buffered detection values, specifications and
anticipated state information resulting in an agitator performance
parameter; and a response circuit structured to perform at least
one operation in response to at the at least one of vibration
amplitude, vibration frequency and vibration phase location and the
agitator performance parameter, wherein the agitator is one of a
rotating tank mixer, a large tank mixer, a portable tank mixers, a
tote tank mixer, a drum mixer, a mounted mixer and a propeller
mixer.
[0685] An example system for estimating a compressor health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage circuit structured to
store specifications, system geometry, and anticipated state
information for a compressor and compressor components associated
with the detection values, store historical compressor performance
and buffer the plurality of detection values for a predetermined
length of time; a timer circuit structured to generate a timing
signal based on a first detected value of the plurality of
detection values; a compressor analysis circuit structured to
analyze buffered detection values relative to specifications and
anticipated state information resulting in a compressor performance
parameter comprising: a phase detection circuit structured to
determine a relative phase difference between a second detection
value of the plurality of detection values and the timing signal;
and a signal evaluation circuit structured to obtain at least one
of vibration amplitude, vibration frequency and vibration phase
location corresponding to a second detected value and analyze the
at least one of vibration amplitude, vibration frequency and
vibration phase location relative to buffered detection values,
specifications and anticipated state information resulting in a
compressor performance parameter; and a response circuit structured
to perform at least one operation in response to at the at least
one of vibration amplitude, vibration frequency and vibration phase
location and the compressor performance parameter.
[0686] An example system for estimating an air conditioner health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage circuit structured to
store specifications, system geometry, and anticipated state
information for an air conditioner and air conditioner components
associated with the detection values, store historical air
conditioner performance and buffer the plurality of detection
values for a predetermined length of time; a timer circuit
structured to generate a timing signal based on a first detected
value of the plurality of detection values; an air conditioner
analysis circuit structured to analyze buffered detection values
relative to specifications and anticipated state information
resulting in an air conditioner performance parameter comprising: a
phase detection circuit structured to determine a relative phase
difference between a second detection value of the plurality of
detection values and the timing signal; and a signal evaluation
circuit structured to obtain at least one of vibration amplitude,
vibration frequency and vibration phase location corresponding to a
second detected value and analyze the at least one of vibration
amplitude, vibration frequency and vibration phase location
relative to buffered detection values, specifications and
anticipated state information resulting in an air conditioner
performance parameter; and a response circuit structured to perform
at least one operation in response to at the at least one of
vibration amplitude, vibration frequency and vibration phase
location and the air conditioner performance parameter.
[0687] An example system for estimating a centrifuge health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage circuit structured to
store specifications, system geometry, and anticipated state
information for a centrifuge and centrifuge components associated
with the detection values, store historical centrifuge performance
and buffer the plurality of detection values for a predetermined
length of time; a timer circuit structured to generate a timing
signal based on a first detected value of the plurality of
detection values; a centrifuge analysis circuit structured to
analyze buffered detection values relative to specifications and
anticipated state information resulting in a centrifuge performance
parameter comprising: a phase detection circuit structured to
determine a relative phase difference between a second detection
value of the plurality of detection values and the timing signal;
and a signal evaluation circuit structured to obtain at least one
of vibration amplitude, vibration frequency and vibration phase
location corresponding to a second detected value and analyze the
at least one of vibration amplitude, vibration frequency and
vibration phase location relative to buffered detection values,
specifications and anticipated state information resulting in a
centrifuge performance parameter; and a response circuit structured
to perform at least one operation in response to at the at least
one of vibration amplitude, vibration frequency and vibration phase
location and the centrifuge performance parameter.
[0688] In embodiments, information about the health of a component
or piece of industrial equipment may be obtained by comparing the
values of multiple signals at the same point in a process. This may
be accomplished by aligning a signal relative to other related data
signals, timers, or reference signals. An embodiment of a data
monitoring device 8700, 8718 is shown in FIGS. 67-69 and may
include a controller 8702, 8720. The controller may include a data
acquisition circuit 8704, 8722, a signal evaluation circuit 8708, a
data storage circuit 8716 and an optional response circuit 8710.
The signal evaluation circuit 8708 may comprise a timer circuit
8714 and, optionally, a phase detection circuit 8712.
[0689] The data monitoring device may include a plurality of
sensors 8706 communicatively coupled to a controller 8702. The
plurality of sensors 8706 may be wired to ports on the data
acquisition circuit 8704. The plurality of sensors 8706 may be
wirelessly connected to the data acquisition circuit 8704 which may
be able to access detection values corresponding to the output of
at least one of the plurality of sensors 8706 where the sensors
8706 may be capturing data on different operational aspects of a
piece of equipment or an operating component. In embodiments, as
illustrated in FIGS. 68 and 69, one or more external sensors 8724
which are not explicitly part of a monitoring device 8718 may be
opportunistically connected to or accessed by the monitoring device
8718. The data acquisition circuit 8722 may include one or more
input ports 8726. The one or more external sensors 8724 may be
directly connected to the one or more input ports 8726 on the data
acquisition circuit 8722 of the controller 8720. In embodiments, as
shown in FIG. 69, a data acquisition circuit 8722 may further
comprise a wireless communications circuit 8728 to access detection
values corresponding to the one or more external sensors 8724
wirelessly or via a separate source or some combination of these
methods.
[0690] The selection of the plurality of sensors 8706 8724 for
connection to a data monitoring device 8700 8718 designed for a
specific component or piece of equipment may depend on a variety of
considerations such as accessibility for installing new sensors,
incorporation of sensors in the initial design, anticipated
operational and failure conditions, resolution desired at various
positions in a process or plant, reliability of the sensors, and
the like. The impact of a failure, time response of a failure
(e.g., warning time and/or off-nominal modes occurring before
failure), likelihood of failure, and/or sensitivity required and/or
difficulty to detect failed conditions may drive the extent to
which a component or piece of equipment is monitored with more
sensors and/or higher capability sensors being dedicated to systems
where unexpected or undetected failure would be costly or have
severe consequences.
[0691] The signal evaluation circuit 8708 may process the detection
values to obtain information about a component or piece of
equipment being monitored. Information extracted by the signal
evaluation circuit 8708 may comprise information regarding what
point or time in a process corresponds with a detection value where
the point in time is based on a timing signal generated by the
timer circuit 8714. The start of the timing signal may be generated
by detecting an edge of a control signal such as a rising edge,
falling edge or both where the control signal may be associated
with the start of a process. The start of the timing signal may be
triggered by an initial movement of a component or piece of
equipment. The start of the timing signal may be triggered by an
initial flow through a pipe or opening or by a flow achieving a
predetermined rate. The start of the timing signal may be triggered
by a state value indicating a process has commenced--for example
the state of a switch, button, data value provided to indicate the
process has commenced, or the like. Information extracted may
comprise information regarding a difference in phase, determined by
the phase detection circuit 8712, between a stream of detection
value and the time signal generated by the timer circuit 8714.
Information extracted may comprise information regarding a
difference in phase between one stream of detection values and a
second stream of detection values where the first stream of
detection values is used as a basis or trigger for a timing signal
generated by the timer circuit.
[0692] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating and
the like, sensors 8706 8724 may comprise one or more of, without
limitation, a thermometer, a hygrometer, a voltage sensor, a
current sensor, an accelerometer, a velocity detector, a light or
electromagnetic sensor (e.g., determining temperature, composition
and/or spectral analysis, and/or object position or movement), an
image sensor, a displacement sensor, a turbidity meter, a viscosity
meter, a load sensor, a tri-axial sensor, a tachometer, a fluid
pressure meter, an air flow meter, a horsepower meter, a flow rate
meter, a fluid particle detector, an acoustical sensor, a pH
sensor, and the like.
[0693] The sensors 8706 8724 may provide a stream of data over time
that has a phase component, such as acceleration or vibration,
allowing for the evaluation of phase or frequency analysis of
different operational aspects of a piece of equipment or an
operating component. The sensors 8706 8724 may provide a stream of
data that is not phase based such as temperature, humidity, load,
and the like. The sensors 8706 8724 may provide a continuous or
near continuous stream of data over time, periodic readings,
event-driven readings, and/or readings according to a selected
interval or schedule.
[0694] In embodiments, as illustrated in FIGS. 70 and 71, the data
acquisition circuit 8734 may further comprise a multiplexer circuit
8736 as described elsewhere herein. Outputs from the multiplexer
circuit 8736 may be utilized by the signal evaluation circuit 8708.
The response circuit 8710 may have the ability to turn on and off
portions of the multiplexer circuit 8736. The response circuit 8710
may have the ability to control the control channels of the
multiplexer circuit 8736
[0695] The response circuit 8710 may further comprise evaluating
the results of the signal evaluation circuit 8708 and, based on
certain criteria, initiating an action. The criteria may include a
sensor's detection values at certain frequencies or phases relative
to the timer signal where the frequencies or phases of interest may
be based on the equipment geometry, equipment control schemes,
system input, historical data, current operating conditions, and/or
an anticipated response. Criteria may include a predetermined
maximum or minimum value for a detection value from a specific
sensor, a cumulative value of a sensor's corresponding detection
value over time, a change in value, a rate of change in value,
and/or an accumulated value (e.g., a time spent above/below a
threshold value, a weighted time spent above/below one or more
threshold values, and/or an area of the detected value above/below
one or more threshold values). The criteria may comprise
combinations of data from different sensors such as relative
values, relative changes in value, relative rates of change in
value, relative values over time, and the like. The relative
criteria may change with other data or information such as process
stage, type of product being processed, type of equipment, ambient
temperature and humidity, external vibrations from other equipment,
and the like.
[0696] Certain embodiments are described herein as detected values
exceeding thresholds or predetermined values, but detected values
may also fall below thresholds or predetermined values--for example
where an amount of change in the detected value is expected to
occur, but detected values indicate that the change may not have
occurred. For example, and without limitation, vibrational data may
indicate system agitation levels, properly operating equipment, or
the like, and vibrational data below amplitude and/or frequency
thresholds may be an indication of a process that is not operating
according to expectations. Except where the context clearly
indicates otherwise, any description herein describing a
determination of a value above a threshold and/or exceeding a
predetermined or expected value is understood to include
determination of a value below a threshold and/or falling below a
predetermined or expected value.
[0697] The predetermined acceptable range may be based on
anticipated system response or vibration based on the equipment
geometry and control scheme such as number of bearings, relative
rotational speed, influx of power to the system at a certain
frequency, and the like. The predetermined acceptable range may
also be based on long term analysis of detection values across a
plurality of similar equipment and components and correlation of
data with equipment failure.
[0698] In some embodiments, an alert may be issued based on the
some of the criteria discussed above. In an illustrative example,
an increase in temperature and energy at certain frequencies may
indicate a hot bearing that is starting to fail. In embodiments,
the relative criteria for an alarm may change with other data or
information such as process stage, type of product being processed
on equipment, ambient temperature and humidity, external vibrations
from other equipment and the like. In an illustrative and
non-limiting example, the response circuit 8710 may initiate an
alert if a vibrational amplitude and/or frequency exceeds a
predetermined maximum value, if there is a change or rate of change
that exceeds a predetermined acceptable range, and/or if an
accumulated value based on vibrational amplitude and/or frequency
exceeds a threshold.
[0699] In embodiments, response circuit 8710 may cause the data
acquisition circuit 8704 to enable or disable the processing of
detection values corresponding to certain sensors based on the some
of the criteria discussed above. This may include switching to
sensors having different response rates, sensitivity, ranges, and
the like; accessing new sensors or types of sensors, and the like.
This switching may be implemented by changing the control signals
for a multiplexer circuit 8736 and/or by turning on or off certain
input sections of the multiplexer circuit 8736. The response
circuit 8710 may make recommendations for the replacement of
certain sensors in the future with sensors having different
response rates, sensitivity, ranges, and the like. The response
circuit 8710 may recommend design alterations for future
embodiments of the component, the piece of equipment, the operating
conditions, the process, and the like.
[0700] In embodiments, the response circuit 8710 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call. The response circuit 8710 may recommend changes in process or
operating parameters to remotely balance the piece of equipment. In
embodiments, the response circuit 8710 may implement or recommend
process changes--for example to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but still at least partially
operational. In an illustrative example, vibration phase
information, derived by the phase detection circuit 8712 relative
to a timer signal from the timer circuit 8714, may be indicative of
a physical location of a problem. Based on the vibration phase
information, system design flaws, off-nominal operation, and/or
component or process failures may be identified.
[0701] In embodiments, based on relevant operating conditions
and/or failure modes which may occur in as sensor values approach
one or more criteria, the signal evaluation circuit 8708 may store
data in the data storage circuit 8716 based on the fit of data
relative to one or more criteria. Based on one sensor input meeting
or approaching specified criteria or range, the signal evaluation
circuit 8708 may store additional data such as RPMs, component
loads, temperatures, pressures, vibrations in the data storage
circuit 8716. The signal evaluation circuit 8708 may store data at
a higher data rate for greater granularity in future processing,
the ability to reprocess at different sampling rates, and/or to
enable diagnosing or post-processing of system information where
operational data of interest is flagged, and the like.
[0702] In embodiments, as shown in FIGS. 72 and 73 and 74 and 75, a
data monitoring system 8762 may include at least one data
monitoring device 8768. The at least one data monitoring device
8768 may include sensors 8706 and a controller 8770 comprising a
data acquisition circuit 8704, a signal evaluation circuit 8772, a
data storage circuit 8742, and a communications circuit 8752 to
allow data and analysis to be transmitted to a monitoring
application 8776 on a remote server 8774. The signal evaluation
circuit 8772 may include at least one of a phase detection circuit
8712 and a timer circuit 8714. The signal evaluation circuit 8772
may periodically share data with the communication circuit 8752 for
transmittal to the remote server 8774 to enable the tracking of
component and equipment performance over time and under varying
conditions by a monitoring application 8776. Because relevant
operating conditions and/or failure modes may occur as sensor
values approach one or more criteria, the signal evaluation circuit
8708 may share data with the communication circuit 8752 for
transmittal to the remote server 8774 based on the fit of data
relative to one or more criteria. Based on one sensor input meeting
or approaching specified criteria or range, the signal evaluation
circuit 8708 may share additional data such as RPMs, component
loads, temperatures, pressures, vibrations, and the like for
transmittal. The signal evaluation circuit 8772 may share data at a
higher data rate for transmittal to enable greater granularity in
processing on the remote server.
[0703] In embodiments, as shown in FIG. 72, the communications
circuit 8752 may communicated data directly to a remote server
8774. In embodiments, as shown in FIG. 73, the communications
circuit 8752 may communicate data to an intermediate computer 8754
which may include a processor 8756 running an operating system 8758
and a data storage circuit 8760. The intermediate computer 8754 may
collect data from a plurality of data monitoring devices and send
the cumulative data to the remote server 8774.
[0704] In embodiments as illustrated in FIGS. 74 and 75, a data
collection system 8762 may have a plurality of monitoring devices
8768 collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment, (both the same and different types of
equipment) in the same facility as well as collecting data from
monitoring devices in multiple facilities. In embodiments, as show
in in FIG. 74 the communications circuit 8752 may communicated data
directly to a remote server 8774. In embodiments, as shown in FIG.
75, the communications circuit 8752 may communicate data to an
intermediate computer 8754 which may include a processor 8756
running an operating system 8758 and a data storage circuit 8760.
The intermediate computer 8754 may collect data from a plurality of
data monitoring devices and send the cumulative data to the remote
server 8774.
[0705] In embodiments, a monitoring application 8776 on a remote
server 8774 may receive and store one or more of detection values,
timing signals and data coming from a plurality of the various
monitoring devices 8768. The monitoring application 8776 may then
select subsets of the detection values, timing signals and data to
be jointly analyzed. Subsets for analysis may be selected based on
a single type of component or a single type of equipment in which a
component is operating. Subsets for analysis may be selected or
grouped based on common operating conditions such as size of load,
operational condition (e.g., intermittent, continuous, process
stage), operating speed or tachometer, common ambient environmental
conditions such as humidity, temperature, air or fluid particulate,
and the like. Subsets for analysis may be selected based on the
effects of other nearby equipment such as nearby machines rotating
at similar frequencies.
[0706] The monitoring application 8776 may then analyze the
selected subset. In an illustrative example, data from a single
component may be analyzed over different time periods such as one
operating cycle, several operating cycles, a month, a year, the
life of the component or the like. Data from multiple components of
the same type may also be analyzed over different time periods.
Trends in the data such as changes in frequency or amplitude may be
correlated with failure and maintenance records associated with the
same or a related component or piece of equipment. Trends in the
data such as changing rates of change associated with start-up or
different points in the process may be identified. Additional data
may be introduced into the analysis such as output product quality,
indicated success or failure of a process, and the like.
Correlation of trends and values for different types of data may be
analyzed to identify those parameters whose short-term analysis
might provide the best prediction regarding expected performance.
This information may be transmitted back to the monitoring device
to update types of data collected and analyzed locally or to
influence the design of future monitoring devices.
[0707] In an illustrative and non-limiting example, a monitoring
device 8768 may be used to collect and process sensor data to
measure mechanical torque. The monitoring device 8768 may be in
communication with or include a high resolution, high speed
vibration sensor to collect data over a period of time sufficient
to measure multiple cycles of rotation. For gear driven components,
the sampling resolution of the sensor should be such that the
number of samples taken per cycle is at least equal to the number
of gear teeth driving the component. It will be understood that a
lower sampling resolution may also be utilized, which may result in
a lower confidence determination and/or taking data over a longer
period of time to develop sufficient statistical confidence. This
data may then be used in the generation of a phase reference
(relative probe) or tachometer signal for a piece of equipment.
This phase reference may be used directly or used by the timer
circuit 8714 to generate a timing signal to align phase data such
as vibrational data or acceleration data from multiple sensors
located at different positions on a component or on different
components within a system. This information may facilitate the
determination of torque for different components or the generation
of an Operational Deflection Shape (ODS).
[0708] A higher resolution data stream may also provide additional
data for the detection of transitory signals in low speed
operations. The identification of transitory signals may enable the
identification of defects in a piece of equipment or component
operating a low RPMs.
[0709] In an illustrative and non-limiting example, the monitoring
device may be used to identify mechanical jitter for use in failure
prediction models. The monitoring device may begin acquiring data
when the piece of equipment starts up, through ramping up to
operating speed, and then during operation. Once at operating
speed, it is anticipated that the torsional jitter should be
minimal or within expected ranges, and changes in torsion during
this phase may be indicative of cracks, bearing faults, and the
like. Additionally, known torsions may be removed from the signal
to facilitate in the identification of unanticipated torsions
resulting from system design flaws, component wear, or unexpected
process events. Having phase information associated with the data
collected at operating speed may facilitate identification of a
location of vibration and potential component wear, and/or may be
further correlated to a type of failure for a component. Relative
phase information for a plurality of sensors located throughout a
machine may facilitate the evaluation of torsion as it is
propagated through a piece of equipment.
[0710] In embodiments, the monitoring application 8776 may have
access to equipment specifications, equipment geometry, component
specifications, component materials, anticipated state information
for plurality of component types, operational history, historical
detection values, component life models, and the like for use in
analyzing the selected subset using rule-based or model-based
analysis. In embodiments, the monitoring application 8776 may feed
a neural net with the selected subset to learn to recognize various
operating state, health states (e.g., lifetime predictions) and
fault states utilizing deep learning techniques. In embodiments, a
hybrid of the two techniques (model-based learning and deep
learning) may be used.
[0711] In an illustrative and non-limiting example, component
health of: conveyors and lifters in an assembly line; water pumps
on industrial vehicles; factory air conditioning units; drilling
machines, screw drivers, compressors, pumps, gearboxes, vibrating
conveyors, mixers and motors situated in the oil and gas fields;
factory mineral pumps; centrifuges, and refining tanks situated in
oil and gas refineries; and compressors in gas handling systems may
be monitored using the phase detection and alignment techniques,
data monitoring devices and data collection systems described
herein.
[0712] In an illustrative and non-limiting example, the component
health of equipment to promote chemical reactions deployed in
chemical and pharmaceutical production lines (e.g. rotating
tank/mixer agitators, mechanical/rotating agitators, and propeller
agitators) may be evaluated using the phase detection and alignment
techniques, data monitoring devices and data collection systems
described herein.
[0713] In an illustrative and non-limiting example, the component
health of vehicle steering mechanisms and/or vehicle engines may be
evaluated using the phase detection and alignment techniques, data
monitoring devices and data collection systems described
herein.
[0714] An example monitoring system for data collection, includes a
data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a signal
evaluation circuit comprising: a timer circuit structured to
generate at least one timing signal; and a phase detection circuit
structured to determine a relative phase difference between at
least one of the plurality of detection values and at least one of
the timing signals from the timer circuit; and a response circuit
structured to perform at least one operation in response to the
relative phase difference. In certain further embodiments, an
example system includes:
[0715] wherein the at least one operation is further in response to
at least one of: a change in amplitude of at least one of the
plurality of detection values; a change in frequency or relative
phase of at least one of the plurality of detection values; a rate
of change in both amplitude and relative phase of at least one the
plurality of detection values; and a relative rate of change in
amplitude and relative phase of at least one the plurality of
detection values; wherein the at least one operation comprises
issuing an alert; wherein the alert may be one of haptic, audible
and visual; a data storage circuit, wherein the relative phase
difference and at least one of the detection values and the timing
signal are stored; wherein the at least one operation further
comprises storing additional data in the data storage circuit;
wherein the storing additional data in the data storage circuit is
further in response to at least one of: a change in the relative
phase difference and a relative rate of change in the relative
phase difference; wherein the data acquisition circuit further
comprises at least one multiplexer circuit (MUX) whereby
alternative combinations of detection values may be selected based
on at least one of user input and a selected operating parameter
for a machine, wherein each of the plurality of detection values
corresponds to at least one of the input sensors; wherein the at
least one operation comprises enabling or disabling one or more
portions of the multiplexer circuit, or altering the multiplexer
control lines; wherein the data acquisition circuit comprises at
least two multiplexer circuits and the at least one operation
comprises changing connections between the at least two multiplexer
circuits; and/or the system further comprising a MUX control
circuit structured to interpret a subset of the plurality of
detection values and provide the logical control of the MUX and the
correspondence of MUX input and detected values as a result,
wherein the logic control of the MUX comprises adaptive scheduling
of the select lines.
[0716] An example system for data collection, includes: a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a signal
evaluation circuit comprising: a timer circuit structured to
generate a timing signal based on a first detected value of the
plurality of detection values; and a phase detection circuit
structured to determine a relative phase difference between a
second detection value of the plurality of detection values and the
timing signal; and a phase response circuit structured to perform
at least one operation in response to the phase difference. In
certain further embodiments, an example system includes wherein the
at least one operation is further in response to at least one of: a
change in amplitude of at least one of the plurality of detection
values; a change in frequency or relative phase of at least one of
the plurality of detection values; a rate of change in both
amplitude and relative phase of at least one the plurality of
detection values and a relative rate of change in amplitude and
relative phase of at least one the plurality of detection values;
wherein the at least one operation comprises issuing an alert;
wherein the alert may be one of haptic, audible and visual; where
the system, further includes a data storage circuit; wherein the
relative phase difference and at least one of the detection values
and the timing signal are stored; wherein the at least one
operation further includes storing additional data in the data
storage circuit; wherein the storing additional data in the data
storage circuit is further in response to at least one of: a change
in the relative phase difference and a relative rate of change in
the relative phase difference; wherein the data acquisition circuit
further includes at least one multiplexer (MUX) circuit whereby
alternative combinations of detection values may be selected based
on at least one of user input and a selected operating parameter
for a machine; wherein each of the plurality of detection values
corresponds to at least one of the input sensors; wherein the at
least one operation comprises enabling or disabling one or more
portions of the multiplexer circuit, or altering the multiplexer
control lines; wherein the data acquisition circuit comprises at
least two multiplexer circuits and the at least one operation
comprises changing connections between the at least two multiplexer
circuits; where the system further comprising a MUX control circuit
structured to interpret a subset of the plurality of detection
values and provide the logical control of the MUX and the
correspondence of MUX input and detected values as a result; and/or
wherein the logic control of the MUX comprises adaptive scheduling
of the select lines.
[0717] An example system for data collection, processing, and
utilization of signals in an industrial environment includes a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a signal
evaluation circuit comprising: a timer circuit structured to
generate a timing signal based on a first detected value of the
plurality of detection values; and a phase detection circuit
structured to determine a relative phase difference between a
second detection value of the plurality of detection values and the
timing signal; a data storage facility for storing a subset of the
plurality of detection values and the timing signal; a
communication circuit structured to communicate at least one
selected detection value and the timing signal to a remote server;
and a monitoring application on the remote server structured to
receive the at least one selected detection value and the timing
signal; jointly analyze a subset of the detection values received
from the plurality of monitoring devices; and recommend an action.
In certain embodiments, the example system further includes wherein
joint analysis comprises using the timing signal from each of the
plurality of monitoring devices to align the detection values from
the plurality of monitoring devices and/or wherein the subset of
detection values is selected based on data associated with a
detection value comprising at least one: common type of component,
common type of equipment, and common operating conditions.
[0718] An example system for data collection in an industrial
environment, includes: a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors communicatively coupled to the data acquisition
circuit, the data acquisition circuit comprising a multiplexer
circuit whereby alternative combinations of the detection values
may be selected based on at least one of user input, a detected
state and a selected operating parameter for a machine, each of the
plurality of detection values corresponding to at least one of the
input sensors; a signal evaluation circuit comprising: a timer
circuit structured to generate a timing signal; and a phase
detection circuit structured to determine a relative phase
difference between at least one of the plurality of detection
values and a signal from the timer circuit; and a response circuit
structured to perform at least one operation in response to the
phase difference.
[0719] An example monitoring system for data collection in a piece
of equipment, includes a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors communicatively coupled to the data acquisition
circuit; a timer circuit structured to generate a timing signal
based on a first detected value of the plurality of detection
values; a signal evaluation circuit structured to obtain at least
one of vibration amplitude, vibration frequency and vibration phase
location corresponding to a second detected value comprising: a
phase detection circuit structured to determine a relative phase
difference between a second detection value of the plurality of
detection values and the timing signal; and a response circuit
structured to perform at least one operation in response to at the
at least one of the vibration amplitude, vibration frequency and
vibration phase location.
[0720] A monitoring system for bearing analysis in an industrial
environment, the monitoring device includes: a data acquisition
circuit structured to interpret a plurality of detection values,
each of the plurality of detection values corresponding to at least
one of a plurality of input sensors communicatively coupled to the
data acquisition circuit; a timer circuit structured to generate a
timing signal a data storage for storing specifications and
anticipated state information for a plurality of bearing types and
buffering the plurality of detection values for a predetermined
length of time; a timer circuit structured to generate a timing
signal based on a first detected value of the plurality of
detection values; a bearing analysis circuit structured to analyze
buffered detection values relative to specifications and
anticipated state information resulting in a life prediction
comprising: a phase detection circuit structured to determine a
relative phase difference between a second detection value of the
plurality of detection values and the timing signal; a signal
evaluation circuit structured to obtain at least one of vibration
amplitude, vibration frequency and vibration phase location
corresponding to a second detected value: and a response circuit
structured to perform at least one operation in response to at the
at least one of the vibration amplitude, vibration frequency and
vibration phase location.
[0721] In embodiments, information about the health or other status
or state information of or regarding a component or piece of
industrial equipment may be obtained by monitoring the condition of
various components throughout a process. Monitoring may include
monitoring the amplitude of a sensor signal measuring attributes
such as temperature, humidity, acceleration, displacement and the
like. An embodiment of a data monitoring device 9000 is shown in
FIG. 76 and may include a plurality of sensors 9006 communicatively
coupled to a controller 9002. The controller 9002, which may be
part of a data collection device, such as a mobile data collector,
or part of a system, such as a network-deployed or cloud-deployed
system, may include a data acquisition circuit 9004, a signal
evaluation circuit 9008 and a response circuit 9010. The signal
evaluation circuit 9008 may comprise a peak detection circuit 9012.
Additionally, the signal evaluation circuit 9008 may optionally
comprise one or more of a phase detection circuit 9016, a bandpass
filter circuit 9018, a phase lock loop circuit, a torsional
analysis circuit, a bearing analysis circuit, and the like. The
bandpass filter 9018 may be used to filter a stream of detection
values such that values, such as peaks and valleys, are detected
only at or within bands of interest, such as frequencies of
interest. The data acquisition circuit 9004 may include one or more
analog-to-digital converter circuits 9014. A peak amplitude
detected by the peak detection circuit 9012 may be input into one
or more analog-to-digital converter circuits 9014 to provide a
reference value for scaling output of the analog-to-digital
converter circuits 9014 appropriately.
[0722] The plurality of sensors 9006 may be wired to ports on the
data acquisition circuit 9004. The plurality of sensors 9006 may be
wirelessly connected to the data acquisition circuit 9004. The data
acquisition circuit 9004 may be able to access detection values
corresponding to the output of at least one of the plurality of
sensors 9006 where the sensors 9006 may be capturing data on
different operational aspects of a piece of equipment or an
operating component.
[0723] The selection of the plurality of sensors 9006 for a data
monitoring device 9000 designed for a specific component or piece
of equipment may depend on a variety of considerations such as
accessibility for installing new sensors, incorporation of sensors
in the initial design, anticipated operational and failure
conditions, resolution desired at various positions in a process or
plant, reliability of the sensors, power availability, power
utilization, storage utilization, and the like. The impact of a
failure, time response of a failure (e.g., warning time and/or
off-optimal modes occurring before failure), likelihood of failure,
extent of impact of failure, and/or sensitivity required and/or
difficulty to detection failure conditions may drive the extent to
which a component or piece of equipment is monitored with more
sensors and/or higher capability sensors being dedicated to systems
where unexpected or undetected failure would be costly or have
severe consequences.
[0724] The signal evaluation circuit 9008 may process the detection
values to obtain information about a component or piece of
equipment being monitored. Information extracted by the signal
evaluation circuit 9008 may comprise information regarding a peak
value of a signal such as a peak temperature, peak acceleration,
peak velocity, peak pressure, peak weight bearing, peak strain,
peak bending, or peak displacement. The peak detection may be done
using analog or digital circuits. In embodiments, the peak
detection circuit 9012 may be able to distinguish between "local"
or short term peaks in a stream of detection values and a "global"
or longer term peak. In embodiments, the peak detection circuit
9012 may be able to identify peak shapes (not just a single peak
value) such as flat tops, asymptotic approaches, discrete jumps in
the peak value or rapid/steep climbs in peak value, sinusoidal
behavior within ranges and the like. Flat topped peaks may indicate
saturation at of a sensor. Asymptotic approaches to a peak may
indicate linear system behavior. Discrete jumps in value or steep
changes in peak value may indicate quantized or nonlinear behavior
of either the sensor doing the measurement or the behavior of the
component. In embodiments, the system may be able to identify
sinusoidal variations in the peak value within an envelope, such as
an envelope established by line or curve connecting a series of
peak values. It should be noted that references to "peaks" should
be understood to encompass one or more "valleys," representing a
series of low points in measurement, except where context indicates
otherwise.
[0725] In embodiments, a peak value may be used as a reference for
an analog-to-digital conversion circuit 9014.
[0726] In an illustrative and non-limiting example, a temperature
probe may measure the temperature of a gear as it rotates in a
machine. The peak temperature may be detected by a peak detection
circuit 9012. The peak temperature may be fed into an
analog-to-digital converter circuit 9014 to appropriately scale a
stream of detection values corresponding to temperature readings of
the gear as it rotates in a machine. The phase of the stream of
detection values corresponding to temperature relative to an
orientation of the gear may be determined by the phase detection
circuit 9016. Knowing where in the rotation of the gear a peak
temperature is occurring may allow the identification of a bad gear
tooth.
[0727] In some embodiments, two or more sets of detection values
may be fused to create detection values for a virtual sensor. A
peak detection circuit may be used to verify consistency in timing
of peak values between at least one of the two or more sets of
detection values and the detection values for the virtual
sensor.
[0728] In embodiments, the signal evaluation circuit 9008 may be
able to reset the peak detection circuit 9012 upon start-up of the
monitoring device 9000, upon edge detection of a control signal of
the system being monitored, based on a user input, after a system
error and the like. In embodiments, the signal evaluation circuit
9008 may discard an initial portion of the output of the peak
detection circuit 9012 prior to using the peak value as a reference
value for an analog-to-digital conversion circuit to allow the
system to fully come on line.
[0729] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating and
the like, sensors 9006 may comprise one or more of, without
limitation, a vibration sensor, a thermometer, a hygrometer, a
voltage sensor, a current sensor, an accelerometer, a velocity
detector, a light or electromagnetic sensor (e.g., determining
temperature, composition and/or spectral analysis, and/or object
position or movement), an image sensor, a structured light sensor,
a laser-based image sensor, an acoustic wave sensor, a displacement
sensor, a turbidity meter, a viscosity meter, a load sensor, a
tri-axial sensor, an accelerometer, a tachometer, a fluid pressure
meter, an air flow meter, a horsepower meter, a flow rate meter, a
fluid particle detector, an acoustical sensor, a pH sensor, and the
like, including, without limitation, any of the sensors described
throughout this disclosure and the documents incorporated by
reference.
[0730] The sensors 9006 may provide a stream of data over time that
has a phase component, such as relating to acceleration or
vibration, allowing for the evaluation of phase or frequency
analysis of different operational aspects of a piece of equipment
or an operating component. The sensors 9006 may provide a stream of
data that is not conventionally phase-based, such as temperature,
humidity, load, and the like. The sensors 9006 may provide a
continuous or near continuous stream of data over time, periodic
readings, event-driven readings, and/or readings according to a
selected interval or schedule.
[0731] In embodiments, as illustrated in FIG. 76, the sensors 9006
may be part of the data monitoring device 9000, referred to herein
in some cases as a data collector, which in some cases may comprise
a mobile or portable data collector. In embodiments, as illustrated
in FIGS. 77 and 78, one or more external sensors 9026, which are
not explicitly part of a monitoring device 9020 but rather are new,
previously attached to or integrated into the equipment or
component, may be opportunistically connected to or accessed by the
monitoring device 9020. The monitoring device 9020 may include a
controller 9022. The controller 9022 may include a response circuit
9010, a signal evaluation circuit 9008 and a data acquisition
circuit 9024. The signal evaluation circuit 9008 may include a peak
detection circuit 9012 and optionally a phase detection circuit
9016 and/or a bandpass filter circuit 9018. The data acquisition
circuit 9024 may include one or more input ports 9028. The one or
more external sensors 9026 may be directly connected to the one or
more input ports 9028 on the data acquisition circuit 9024 of the
controller 9022 or may be accessed by the data acquisition circuit
9004 wirelessly, such as by a reader, interrogator, or other
wireless connection, such as over a short-distance wireless
protocol. In embodiments as shown in FIG. 78, a data acquisition
circuit 9024 may further comprise a wireless communication circuit
9030. The data acquisition circuit 9024 may use the wireless
communication circuit 9030 to access detection values corresponding
to the one or more external sensors 9026 wirelessly or via a
separate source or some combination of these methods.
[0732] In embodiments as illustrated in FIG. 79, the data
acquisition circuit 9036 may further comprise a multiplexer circuit
9038 as described elsewhere herein. Outputs from the multiplexer
circuit 9038 may be utilized by the signal evaluation circuit 9008.
The response circuit 9010 may have the ability to turn on and off
portions of the multiplexor circuit 9038. The response circuit 9010
may have the ability to control the control channels of the
multiplexor circuit 9038
[0733] The response circuit 9010 may evaluate the results of the
signal evaluation circuit 9008 and, based on certain criteria,
initiate an action. The criteria may include a predetermined peak
value for a detection value from a specific sensor, a cumulative
value of a sensor's corresponding detection value over time, a
change in peak value, a rate of change in a peak value, and/or an
accumulated value (e.g., a time spent above/below a threshold
value, a weighted time spent above/below one or more threshold
values, and/or an area of the detected value above/below one or
more threshold values). The criteria may comprise combinations of
data from different sensors such as relative values, relative
changes in value, relative rates of change in value, relative
values over time, and the like. The relative criteria may change
with other data or information such as process stage, type of
product being processed, type of equipment, ambient temperature and
humidity, external vibrations from other equipment, and the like.
The relative criteria may be reflected in one or more calculated
statistics or metrics (including ones generated by further
calculations on multiple criteria or statistics), which in turn may
be used for processing (such as an on-board a data collector or by
an external system), such as to be provided as an input to one or
more of the machine learning capabilities described in this
disclosure, to a control system (which may be on-board a data
collector or remote, such as to control selection of data inputs,
multiplexing of sensor data, storage, or the like), or as a data
element that is an input to another system, such as a data stream
or data package that may be available to a data marketplace, a
SCADA system, a remote control system, a maintenance system, an
analytic system, or other system.
[0734] Certain embodiments are described herein as detected values
exceeding thresholds or predetermined values, but detected values
may also fall below thresholds or predetermined values--for example
where an amount of change in the detected value is expected to
occur, but detected values indicate that the change may not have
occurred. For example, and without limitation, vibrational data may
indicate system agitation levels, properly operating equipment, or
the like, and vibrational data below amplitude and/or frequency
thresholds may be an indication of a process that is not operating
according to expectations. For example, in a process involving a
blender, a mixer, an agitator or the like, the absence of vibration
may indicate that a blade, fin, vane or other working element is
unable to move adequately, such as, for example, as a result of a
working material being excessively viscous or as a result of a
problem in gears (e.g., stripped gears, seizing in gears, or the
like (a clutch, or the like). Except where the context clearly
indicates otherwise, any description herein describing a
determination of a value above a threshold and/or exceeding a
predetermined or expected value is understood to include
determination of a value below a threshold and/or falling below a
predetermined or expected value.
[0735] The predetermined acceptable range may be based on
anticipated system response or vibration based on the equipment
geometry and control scheme such as number of bearings, relative
rotational speed, influx of power to the system at a certain
frequency, and the like. The predetermined acceptable range may
also be based on long term analysis of detection values across a
plurality of similar equipment and components and correlation of
data with equipment failure.
[0736] In embodiments, the response circuit 9010 may issue an alert
based on one or more of the criteria discussed above. In an
illustrative example, an increase in peak temperature beyond a
predetermined value may indicate a hot bearing that is starting to
fail. In embodiments, the relative criteria for an alarm may change
with other data or information such as process stage, type of
product being processed on equipment, ambient temperature and
humidity, external vibrations from other equipment and the like. In
an illustrative and non-limiting example, the response circuit 9010
may initiate an alert if an amplitude, such as a vibrational
amplitude and/or frequency, exceeds a predetermined maximum value,
if there is a change or rate of change that exceeds a predetermined
acceptable range, and/or if an accumulated value based on such
amplitude and/or frequency exceeds a threshold.
[0737] In embodiments, the response circuit 9010 may cause the data
acquisition circuit 9004 to enable or disable the processing of
detection values corresponding to certain sensors based on one or
more of the criteria discussed above. This may include switching to
sensors having different response rates, sensitivity, ranges, and
the like; accessing new sensors or types of sensors, accessing data
from multiple sensors, and the like. Switching may be based on a
detected peak value for the sensor being switched or based on the
peak value of another sensor. Switching may be undertaken based on
a model, a set of rules, or the like. In embodiments, switching may
be under control of a machine learning system, such that switching
is controlled based on one or more metrics of success, combined
with input data, over a set of trials, which may occur under
supervision of a human supervisor or under control of an automated
system. Switching may involve switching from one input port to
another (such as to switch from one sensor to another). Switching
may involve altering the multiplexing of data, such as combining
different streams under different circumstances. Switching may
involve activating a system to obtain additional data, such as
moving a mobile system (such as a robotic or drone system), to a
location where different or additional data is available (such as
positioning an image sensor for a different view or positioning a
sonar sensor for a different direction of collection) or to a
location where different sensors can be accessed (such as moving a
collector to connect up to a sensor that is disposed at a location
in an environment by a wired or wireless connection). This
switching may be implemented by changing the control signals for a
multiplexor circuit 9038 and/or by turning on or off certain input
sections of the multiplexor circuit 9038.
[0738] In embodiments, the response circuit 9010 may adjust a
sensor scaling value using the detected peak as a reference
voltage. The response circuit 9010 may adjust a sensor sampling
rate such that the peak value is captured.
[0739] The response circuit 9010 may identify sensor overload. In
embodiments, the response circuit 9010 may make recommendations for
the replacement of certain sensors in the future with sensors
having different response rates, sensitivity, ranges, and the like.
The response circuit 9010 may recommend design alterations for
future embodiments of the component, the piece of equipment, the
operating conditions, the process, and the like.
[0740] In embodiments, the response circuit 9010 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call where the maintenance may include the replacement of the
sensor with the same or an alternate type of sensor having a
different response rate, sensitivity, range and the like. In
embodiments, the response circuit 9010 may implement or recommend
process changes--for example, to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but still at least partially
operational, to change the operating speed of a component (such as
to put it in a lower-demand mode), to initiate amelioration of an
issue (such as to signal for additional lubrication of a roller
bearing set, or to signal for an alignment process for a system
that is out of balance), and the like.
[0741] In embodiments, as shown in FIG. 80, the data monitoring
device 9040 may include sensors 9006 and a controller 9042 which
may include a data acquisition circuit 9004, and a signal
evaluation circuit 9008. The signal evaluation circuit 9008 may
include a peak detection circuit 9012 and, optionally, a phased
detection circuit 9016 and/or a bandpass filter circuit 9018. The
controller 9042 may further include a data storage circuit 9044,
memory, and the like. The controller 9042 may further include a
response circuit 9010. The signal evaluation circuit 9008 may
periodically store certain detection values in the data storage
circuit 9044 to enable the tracking of component performance over
time.
[0742] In embodiments, based on relevant criteria as described
elsewhere herein, operating conditions and/or failure modes which
may occur as sensor values approach one or more criteria, the
signal evaluation circuit 9008 may store data in the data storage
circuit 9044 based on the fit of data relative to one or more
criteria, such as those described throughout this disclosure. Based
on one sensor input meeting or approaching specified criteria or
range, the signal evaluation circuit 9008 may store additional data
such as RPMs, component loads, temperatures, pressures, vibrations
or other sensor data of the types described throughout this
disclosure in the data storage circuit 9068. The signal evaluation
circuit 9008 may store data at a higher data rate for greater
granularity in future processing, the ability to reprocess at
different sampling rates, and/or to enable diagnosing or
post-processing of system information where operational data of
interest is flagged, and the like.
[0743] In embodiments, the signal evaluation circuit 9008 may store
new peaks that indicate changes in overall scaling over a long
duration (e.g., scaling a data stream based on historical peaks
over months of analysis). The signal evaluation circuit 9008 may
store data when historical peak values are approached (e.g., as
temperatures, pressures, vibrations, velocities, accelerations and
the like approach historical peaks).
[0744] In embodiments as shown in FIGS. 81 and 82 and 83 and 84, a
data monitoring system 9046 may include at least one data
monitoring device 9048. At least one data monitoring device 9048
may include sensors 9006 and a controller 9050 comprising a data
acquisition circuit 9004, a signal evaluation circuit 9008, a data
storage circuit 9044, and a communication circuit 9052 to allow
data and analysis to be transmitted to a monitoring application
9056 on a remote server 9054. The signal evaluation circuit 9008
may include at least one of a peak detection circuit 9012. The
signal evaluation circuit 9008 may periodically share data with the
communication circuit 9052 for transmittal to the remote server
9054 to enable the tracking of component and equipment performance
over time and under varying conditions by a monitoring application
9056. Because relevant operating conditions and/or failure modes
may occur as sensor values approach one or more criteria as
described elsewhere herein, the signal evaluation circuit 9008 may
share data with the communication circuit 9052 for transmittal to
the remote server 9054 based on the fit of data relative to one or
more criteria. Based on one sensor input meeting or approaching
specified criteria or range, the signal evaluation circuit 9008 may
share additional data such as RPMs, component loads, temperatures,
pressures, vibrations, and the like for transmittal. The signal
evaluation circuit 9008 may share data at a higher data rate for
transmittal to enable greater granularity in processing on the
remote server.
[0745] In embodiments, as shown in FIG. 81, the communication
circuit 9052 may communicate data directly to a remote server 9054.
In embodiments, as shown in FIG. 82, the communication circuit 9052
may communicate data to an intermediate computer 9058 which may
include a processor 9060 running an operating system 9062 and a
data storage circuit 9064.
[0746] In embodiments, as illustrated in FIGS. 83 and 84, a data
collection system 9066 may have a plurality of monitoring devices
9048 collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment (both the same and different types of
equipment) in the same facility as well as collecting data from
monitoring devices in multiple facilities. A monitoring application
9056 on a remote server 9054 may receive and store one or more of
detection values, timing signals or data coming from a plurality of
the various monitoring devices 9048.
[0747] In embodiments, as shown in FIG. 81, the communication
circuit 9052 may communicate data directly to a remote server 9054.
In embodiments, as shown in FIG. 82, the communication circuit 9052
may communicate data to an intermediate computer 9058 which may
include a processor 9060 running an operating system 9062 and a
data storage circuit 9064. There may be an individual intermediate
computer 9058 associated with each monitoring device 9048 or an
individual intermediate computer 9058 may be associated with a
plurality of monitoring devices 9048 where the intermediate
computer 9058 may collect data from a plurality of data monitoring
devices and send the cumulative data to the remote server 9054.
[0748] The monitoring application 9056 may select subsets of the
detection values, timing signals and data to be jointly analyzed.
Subsets for analysis may be selected based on a single type of
component or a single type of equipment in which a component is
operating. Subsets for analysis may be selected or grouped based on
common operating conditions such as size of load, operational
condition (e.g., intermittent, continuous), operating speed or
tachometer, common ambient environmental conditions such as
humidity, temperature, air or fluid particulate, and the like.
Subsets for analysis may be selected based on the effects of other
nearby equipment such as nearby machines rotating at similar
frequencies, nearby equipment producing electromagnetic fields,
nearby equipment producing heat, nearby equipment inducing movement
or vibration, nearby equipment emitting vapors, chemicals or
particulates, or other potentially interfering or intervening
effects.
[0749] The monitoring application 9056 may then analyze the
selected subset. In an illustrative example, data from a single
component may be analyzed over different time periods such as one
operating cycle, several operating cycles, a month, a year, the
life of the component or the like. Data from multiple components of
the same type may also be analyzed over different time periods.
Trends in the data such as changes in frequency or amplitude may be
correlated with failure and maintenance records associated with the
same or a related component or piece of equipment. Trends in the
data, such as changing rates of change associated with start-up or
different points in the process, may be identified. Additional data
may be introduced into the analysis such as output product quality,
output quantity (such as per unit of time), indicated success or
failure of a process, and the like. Correlation of trends and
values for different types of data may be analyzed to identify
those parameters whose short-term analysis might provide the best
prediction regarding expected performance. This information may be
transmitted back to the monitoring device to update types of data
collected and analyzed locally or to influence the design of future
monitoring devices.
[0750] In embodiments, the monitoring application 9056 may have
access to equipment specifications, equipment geometry, component
specifications, component materials, anticipated state information
for a plurality of component types, operational history, historical
detection values, component life models and the like for use
analyzing the selected subset using rule-based or model-based
analysis. In embodiments, the monitoring application 9056 may feed
a neural net with the selected subset to learn to recognize peaks
in waveform patterns by feeding a large data set sample of waveform
behavior of a given type within which peaks are designated (such as
by human analysts).
[0751] A monitoring system for data collection in an industrial
environment, the monitoring system comprising: a data acquisition
circuit structured to interpret a plurality of detection values
from a plurality of input sensors communicatively coupled to the
data acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a peak
detection circuit structured to determine at least one peak value
in response to the plurality of detection values; and a peak
response circuit structured to perform at least one operation in
response to the at least one peak value.
[0752] An example monitoring system further includes: wherein the
at least one operation is further in response to at least one of: a
change in amplitude of at least one of the plurality of detection
values; a change in frequency or relative phase of at least one of
the plurality of detection values; a rate of change in both
amplitude and relative phase of at least one of the plurality of
detection values; and a relative rate of change in amplitude and
relative phase of at least one of the plurality of detection
values' wherein the at least one operation comprises issuing an
alert; wherein the alert may be one of haptic, audible or visual;
further comprising a data storage circuit, wherein the relative
phase difference and at least one of the detection values and the
timing signal are stored wherein the at least one operation further
comprises storing additional data in the data storage circuit
wherein the storing additional data in the data storage circuit is
further in response to at least one of: a change in the relative
phase difference and a relative rate of change in the relative
phase difference wherein the data acquisition circuit further
comprises at least one multiplexer circuit whereby alternative
combinations of detection values may be selected based on at least
one of user input and a selected operating parameter for a machine,
wherein each of the plurality of detection values corresponds to at
least one of the input sensors wherein the at least one operation
comprises enabling or disabling one or more portions of the
multiplexer circuit, or altering the multiplexer control lines
wherein the data acquisition circuit comprises at least two
multiplexer circuits and the at least one operation comprises
changing connections between the at least two multiplexer
circuits.
[0753] A monitoring system for data collection in an industrial
environment, the monitoring system structure to receive input
corresponding to a plurality of sensors, includes a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input sensors; a peak
detection circuit structured to determine at least one peak value
in response to the plurality of detection values; and a peak
response circuit structured to perform at least one operation in
response to the at least one peak value.
[0754] An example monitoring system further includes: wherein the
at least one operation is further in response to at least one of: a
change in amplitude of at least one of the plurality of detection
values; a change in frequency or relative phase of at least one of
the plurality of detection values; a rate of change in both
amplitude and relative phase of at least one of the plurality of
detection values; and a relative rate of change in amplitude and
relative phase of at least one of the plurality of detection values
wherein the at least one operation comprises issuing an alert
wherein the alert may be one of haptic, audible or visual further
comprising a data storage circuit, wherein the relative phase
difference and at least one of the detection values and the timing
signal are stored wherein the at least one operation further
comprises storing additional data in the data storage circuit
wherein the storing additional data in the data storage circuit is
further in response to at least one of: a change in the relative
phase difference and a relative rate of change in the relative
phase difference wherein the data acquisition circuit further
comprises at least one multiplexer circuit whereby alternative
combinations of detection values may be selected based on at least
one of user input and a selected operating parameter for a machine,
wherein each of the plurality of detection values corresponds to at
least one of the input sensors wherein the at least one operation
comprises enabling or disabling one or more portions of the
multiplexer circuit, or altering the multiplexer control lines
wherein the data acquisition circuit comprises at least two
multiplexer circuits and the at least one operation comprises
changing connections between the at least two multiplexer
circuits.
[0755] An example system for data collection, processing, and
utilization of signals in an industrial environment includes: a
plurality of monitoring devices, each monitoring device comprising:
a data acquisition circuit structured to interpret a plurality of
detection values from a plurality of input sensors communicatively
coupled to the data acquisition circuit, each of the plurality of
detection values corresponding to at least one of the input
sensors; a peak detection circuit structured to determine at least
one peak value in response to the plurality of detection values; a
peak response circuit structured to select at least one detection
value in response to the at least one peak value; a communication
circuit structured to communicate the at least one selected
detection value to a remote server; and a monitoring application on
the remote server structured to: receive the at least one selected
detection value; jointly analyze received detection values from a
subset of the plurality of monitoring devices; and recommend an
action.
[0756] An example system further includes: the system further
structured to subset detection values based on one of anticipated
life of a component associated with detection values, type of the
equipment associated with detection values, and operational
conditions under which detection values were measured; wherein the
analysis of the subset of detection values comprises feeding a
neural net with the subset of detection values and supplemental
information to learn to recognize various operating states, health
states, life expectancies and fault states utilizing deep learning
techniques; wherein the supplemental information comprises one of
component specification, component performance, equipment
specification, equipment performance, maintenance records, repair
records and an anticipated state model wherein the at least one
operation is further in response to at least one of: a change in
amplitude of at least one of the plurality of detection values; a
change in frequency or relative phase of at least one of the
plurality of detection values; a rate of change in both amplitude
and relative phase of at least one the plurality of detection
values; and a relative rate of change in amplitude and relative
phase of at least one the plurality of detection values wherein the
at least one operation comprises issuing an alert wherein the alert
may be one of haptic, audible and visual further comprising a data
storage circuit, wherein the relative phase difference and at least
one of the detection values and the timing signal are stored
wherein the at least one operation further comprises storing
additional data in the data storage circuit wherein the storing
additional data in the data storage circuit is further in response
to at least one of: a change in the relative phase difference and a
relative rate of change in the relative phase difference wherein
the data acquisition circuit further comprises at least one
multiplexer circuit whereby alternative combinations of detection
values may be selected based on at least one of user input and a
selected operating parameter for a machine, wherein each of the
plurality of detection values corresponds to at least one of the
input sensors wherein the at least one operation comprises enabling
or disabling one or more portions of the multiplexer circuit, or
altering the multiplexer control lines and/or wherein the data
acquisition circuit comprises at least two multiplexer circuits and
the at least one operation comprises changing connections between
the at least two multiplexer circuits.
[0757] An example motor monitoring system, includes: a data
acquisition circuit structured to interpret a plurality of
detection values from a plurality of input sensors communicatively
coupled to the data acquisition circuit, each of the plurality of
detection values corresponding to at least one of the input
sensors; a data storage circuit structured to store specifications,
system geometry, and anticipated state information for the motor
and motor components, store historical motor performance and buffer
the plurality of detection values for a predetermined length of
time; a peak detection circuit structured to determine a plurality
of peak values comprising at least a temperature peak value, a
speed peak value and a vibration peak value in response to the
plurality of detection values and analyze the peak values relative
to buffered detection values, specifications and anticipated state
information resulting in a motor performance parameter; and a peak
response circuit structured to perform at least one operation in
response to one of a peak value and a motor system performance
parameter.
[0758] An example system for estimating a vehicle steering system
performance parameter, the device includes: a data acquisition
circuit structured to interpret a plurality of detection values
from a plurality of input sensors communicatively coupled to the
data acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for the vehicle steering system, the
rack, the pinion, and the steering column, store historical
steering system performance and buffer the plurality of detection
values for a predetermined length of time; a peak detection circuit
structured to determine a plurality of peak values comprising at
least a temperature peak value, a speed peak value and a vibration
peak value in response to the plurality of detection values and
analyze the peak values relative to buffered detection values,
specifications and anticipated state information resulting in a
vehicle steering system performance parameter; and a peak response
circuit structured to perform at least one operation in response to
one of a peak value and a vehicle steering system performance
parameter.
[0759] An example system for estimating a pump performance
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values from a plurality of input
sensors communicatively coupled to the data acquisition circuit,
each of the plurality of detection values corresponding to at least
one of the input sensors; a data storage circuit structured to
store specifications, system geometry, and anticipated state
information for the pump and pump components associated with the
detection values, store historical pump performance and buffer the
plurality of detection values for a predetermined length of time; a
peak detection circuit structured to determine a plurality of peak
values comprising at least a temperature peak value, a speed peak
value and a vibration peak value in response to the plurality of
detection values and analyze the peak values relative to buffered
detection values, specifications and anticipated state information
resulting in a pump performance parameter; and a peak response
circuit structured to perform at least one operation in response to
one of a peak value and a pump performance parameter. In certain
further embodiments, the example system includes wherein the pump
is a water pump in a car and wherein the pump is a mineral
pump.
[0760] An example system for estimating a drill performance
parameter for a drilling machine, includes a data acquisition
circuit structured to interpret a plurality of detection values
from a plurality of input sensors communicatively coupled to the
data acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for the drill and drill components
associated with the detection values, store historical drill
performance and buffer the plurality of detection values for a
predetermined length of time; a peak detection circuit structured
to determine a plurality of peak values comprising at least a
temperature peak value, a speed peak value and a vibration peak
value in response to the plurality of detection values and analyze
the peak values relative to buffered detection values,
specifications and anticipated state information resulting in a
drill performance parameter; and a peak response circuit structured
to perform at least one operation in response to one of a peak
value and a drill performance parameter. An example system further
includes wherein the drilling machine is one of an oil drilling
machine and a gas drilling machine.
[0761] An example system for estimating a conveyor health
parameter, the system includes: a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for a conveyor and conveyor
components associated with the detection values, store historical
conveyor performance and buffer the plurality of detection values
for a predetermined length of time; a peak detection circuit
structured to determine a plurality of peak values comprising at
least a temperature peak value, a speed peak value and a vibration
peak value in response to the plurality of detection values and
analyze the peak values relative to buffered detection values,
specifications and anticipated state information resulting in a
conveyor performance parameter; and a peak response circuit
structured to perform at least one operation in response to one of
a peak value and a conveyor performance parameter.
[0762] An example system for estimating an agitator health
parameter, the system includes: a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for an agitator and agitator
components associated with the detection values, store historical
agitator performance and buffer the plurality of detection values
for a predetermined length of time; a peak detection circuit
structured to determine a plurality of peak values comprising at
least a temperature peak value, a speed peak value and a vibration
peak value in response to the plurality of detection values and
analyze the peak values relative to buffered detection values,
specifications and anticipated state information resulting in an
agitator performance parameter; and a peak response circuit
structured to perform at least one operation in response to one of
a peak value and an agitator performance parameter. In certain
embodiments, a system further includes where the agitator is one of
a rotating tank mixer, a large tank mixer, a portable tank mixer, a
tote tank mixer, a drum mixer, a mounted mixer and a propeller
mixer.
[0763] An example system for estimating a compressor health
parameter, the system includes: a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for a compressor and compressor
components associated with the detection values, store historical
compressor performance and buffer the plurality of detection values
for a predetermined length of time; a peak detection circuit
structured to determine a plurality of peak values comprising at
least a temperature peak value, a speed peak value and a vibration
peak value in response to the plurality of detection values and
analyze the peak values relative to buffered detection values,
specifications and anticipated state information resulting in a
compressor performance parameter; and a peak response circuit
structured to perform at least one operation in response to one of
a peak value and a compressor performance parameter.
[0764] An example system for estimating an air conditioner health
parameter, the system includes: a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for an air conditioner and air
conditioner components associated with the detection values, store
historical air conditioner performance and buffer the plurality of
detection values for a predetermined length of time; a peak
detection circuit structured to determine a plurality of peak
values comprising at least a temperature peak value, a speed peak
value, a pressure value and a vibration peak value in response to
the plurality of detection values and analyze the peak values
relative to buffered detection values, specifications and
anticipated state information resulting in an air conditioner
performance parameter; and a peak response circuit structured to
perform at least one operation in response to one of a peak value
and an air conditioner performance parameter.
[0765] An example system for estimating a centrifuge health
parameter, the system includes: a data acquisition circuit
structured to interpret a plurality of detection values from a
plurality of input sensors communicatively coupled to the data
acquisition circuit, each of the plurality of detection values
corresponding to at least one of the input sensors; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for a centrifuge and centrifuge
components associated with the detection values, store historical
centrifuge performance and buffer the plurality of detection values
for a predetermined length of time; a peak detection circuit
structured to determine a plurality of peak values comprising at
least a temperature peak value, a speed peak value and a vibration
peak value in response to the plurality of detection values and
analyze the peak values relative to buffered detection values,
specifications and anticipated state information resulting in a
centrifuge performance parameter; and a peak response circuit
structured to perform at least one operation in response to one of
a peak value and a centrifuge performance parameter.
[0766] Bearings are used throughout many different types of
equipment and applications. Bearings may be present in or
supporting shafts, motors, rotors, stators, housings, frames,
suspension systems and components, gears, gear sets of various
types, other bearings, and other elements. Bearings may be used as
support for high speed vehicles such as maglev trains. Bearings are
used to support rotating shafts for engines, motors, generators,
fans, compressors, turbines and the like. Giant roller bearings may
be used to support buildings and physical infrastructure. Different
types of bearings may be used to support conventional, planetary
and other types of gears. Bearings may be used to support
transmissions and gear boxes such as roller thrust bearings, for
example. Bearings may be used to support wheels, wheel hubs and
other rolling parts using tapered roller bearings.
[0767] There are many different types of bearings such as roller
bearings, needle bearings, sleeve bearings, ball bearings, radial
bearings, thrust load bearings including ball thrust bearings used
in low speed applications and roller thrust bearings, taper
bearings and tapered roller bearings, specialized bearings,
magnetic bearings, giant roller bearings, jewel bearings (e.g.,
Sapphire), fluid bearings, flexure bearings to support bending
element loads, and the like. References to bearings throughout this
disclosure is intended to include, but not be limited by, the terms
listed above.
[0768] In embodiments, information about the health or other status
or state information of or regarding a bearing in a piece of
industrial equipment or in an industrial process may be obtained by
monitoring the condition of various components of the industrial
equipment or industrial process. Monitoring may include monitoring
the amplitude and/or frequency and/or phase of a sensor signal
measuring attributes such as temperature, humidity, acceleration,
displacement and the like.
[0769] An embodiment of a data monitoring device 9200 is shown in
FIG. 85 and may include a plurality of sensors 9206 communicatively
coupled to a controller 9202. The controller 9202 may include a
data acquisition circuit 9204, a data storage circuit 9216, a
signal evaluation circuit 9208 and, optionally, a response circuit
9210. The signal evaluation circuit 9208 may comprise a frequency
transformation circuit 9212 and a frequency evaluation circuit
9214.
[0770] The plurality of sensors 9206 may be wired to ports 9226
(reference FIG. 86) on the data acquisition circuit 9204. The
plurality of sensors 9206 may be wirelessly connected to the data
acquisition circuit 9204. The data acquisition circuit 9204 may be
able to access detection values corresponding to the output of at
least one of the plurality of sensors 9206 where the sensors 9206
may be capturing data on different operational aspects of a bearing
or piece of equipment or infrastructure.
[0771] The selection of the plurality of sensors 9206 for a data
monitoring device 9200 designed for a specific bearing or piece of
equipment may depend on a variety of considerations such as
accessibility for installing new sensors, incorporation of sensors
in the initial design, anticipated operational and failure
conditions, reliability of the sensors, and the like. The impact of
failure may drive the extent to which a bearing or piece of
equipment is monitored with more sensors and/or higher capability
sensors being dedicated to systems where unexpected or undetected
bearing failure would be costly or have severe consequences.
[0772] The signal evaluation circuit 9208 may process the detection
values to obtain information about a bearing being monitored. The
frequency transformation circuit 9212 may transform one or more
time-based detection values to frequency information. The
transformation may be accomplished using techniques such as a
digital Fast Fourier transform ("FFT"), Laplace transform,
Z-transform, wavelet transform, other frequency domain transform,
or other digital or analog signal analysis techniques, including,
without limitation, complex analysis, including complex phase
evolution analysis.
[0773] The frequency evaluation circuit 9214 (or frequency analysis
circuit) may be structured to detect signals at frequencies of
interest. Frequencies of interest may include frequencies higher
than the frequency at which the equipment rotates (as measured by a
tachometer, for instance), various harmonics and/or resonant
frequencies associated with the equipment design and operating
conditions such as multiples of shaft rotation velocities or other
rotating components for the equipment that is borne by the
bearings. Changes in energy at frequencies close to the operating
frequency may be an indicator of balance/imbalance in the system.
Changes in energy at frequencies on the order of twice the
operating frequency may be indicative of a system misalignment--for
example, on the coupling, or a looseness in the system, (e.g.,
rattling at harmonics of the operating frequency). Changes in
energy at frequencies close to three or four times the operating
frequency, corresponding to the number of bolts on a coupling, may
indicate wear of on one of the couplings. Changes in energy at
frequencies of four, five, or more times the operating frequency
may relate back to something that has a corresponding number of
elements, such as if there are energy peaks or activity around five
times the operating frequency there may be wear or an imbalance in
a five-vane pump or the like.
[0774] In an illustrative and non-limiting example, in the analysis
of roller bearings, frequencies of interest may include ball spin
frequencies, cage spin frequencies, inner race frequency (as
bearings often sit on a race inside a cage), outer race frequency
and the like. Bearings that are damaged or beginning to fail may
show humps of energy at the frequencies mentioned above and
elsewhere in this disclosure. The energy at these frequencies may
increase over time as the bearings wear more and become more
damaged due to more variations in rotational acceleration and
pings.
[0775] In an illustrative and non-limiting example, bad bearings
may show humps of energy and the intensity of high frequency
measurements may start to grow over time as bearings wear and
become imperfect (greater acceleration and pings may show up in
high frequency measurement domains). Those measurements may be
indicators of air gaps in the bearing system. As bearings begin to
wear, harder hits may cause the energy signal to move to higher
frequencies.
[0776] In embodiments, the signal evaluation circuit 9208 may also
include one or more of a phase detection circuit, a phase lock loop
circuit, a bandpass filter circuit, a peak detection circuit, and
the like.
[0777] In embodiments, the signal evaluation circuit 9208 may
include a transitory signal analysis circuit. Transient signals may
cause small amplitude vibrations. However, the challenge in bearing
analysis is that you may receive a signal associated with a single
or non-periodic impact and an exponential decay. Thus, the
oscillation of the bearing may not be represented by a single sine
wave, but rather by a spectrum of many high frequency sine waves.
For example, a signal from a failing bearing may only be seen, in a
time-based signal, as a low amplitude spike for a short amount of
time. A signal from a failing bearing may be lower in amplitude
than a signal associated with an imbalance even though the
consequences of a failed bearing may be more significant. It is
important to be able to identify these signals. This type of low
amplitude, transient signal may be best analyzed using transient
analysis rather than a conventional frequency transformation, such
as an FFT, which would treat the signal like a low frequency sine
wave. A higher resolution data stream may also provide additional
data for the detection of transitory signals in low speed
operations. The identification of transitory signals may enable the
identification of defects in a piece of equipment or component
operating at low RPMs.
[0778] In embodiments, the transitory signal analysis circuit for
bearing analysis may include envelope modulation analysis and other
transitory signal analysis techniques. The signal evaluation
circuit 9208 may store long stream of detection values to the data
storage circuit 9216. The transitory signal analysis circuit may
use envelope analysis techniques on those long streams of detection
values to identify transient effects (such as impacts) which may
not be identified by conventional sine wave analysis (such as
FFTs).
[0779] The signal evaluation circuit 9208 may utilize transitory
signal analysis models optimized for the type of component being
measured such as bearings, gears, variable speed machinery and the
like. In an illustrative and non-limiting example, a gear may
resonate close to its average rotational speed. In an illustrative
and non-limiting example, a bearing may resonate close to the
bearing rotation frequency and produce a ringing in amplitude
around that frequency. For example, if the shaft inner race is
wearing there may be chatter between the inner race and the shaft
resulting in amplitude modulation to the left and right of the
bearing frequency. The amplitude modulation may demonstrate its own
sine wave characteristics with its own side bands. Various signal
processing techniques may be used to eliminate the sinusoidal
component, resulting in a modulation envelope for analysis.
[0780] The signal evaluation circuit 9208 may be optimized for
variable speed machinery. Historically, variable speed machinery
was expensive to make, and it was common to use DC motors and
variable sheaves, such that flow could be controlled using vanes.
Variable speed motors became more common with solid-state drive
advances ("SCR devices"). The base operating frequency of equipment
may be varied from the 50-60 Hz provided by standard utility
companies and either and slowed down or sped up to run the
equipment at different speeds depending on the application. The
ability to run the equipment at varying speeds may result in energy
savings. However, depending on the equipment geometry, there may be
some speeds which create vibrations at resonant frequencies,
reducing the life of the components. Variable speed motors may also
emit electricity into bearings which may damage the bearings. In
embodiments, the analysis of long data streams for envelope
modulation analysis and other transitory signal analysis techniques
as described herein may be useful in identifying these frequencies
such that control schemes for the equipment may be designed to
avoid those speeds which result in unacceptable vibrations and/or
damage to the bearings.
[0781] In an illustrative and non-limiting example, heating,
ventilation and air conditioning ("HVAC") systems may be assembled
on site using variable speed motors, fans, belts, compressors and
the like where the operating speeds are not constant, and their
relative relationships are unknown. In an illustrative and
non-limiting example, variable speed motors may be used in fan
pumps for building air circulation. Variable speed motors may be
used to vary the speed of conveyors--for example, in manufacturing
assembly lines or steel mills. Variable speed motors may be used
for fans in a pharmaceutical process, such as where it may be
critical to avoid vibration.
[0782] In an illustrative and non-limiting example, sleeve bearings
may be analyzed for defects. Sleeve bearings typically have an oil
system. If the oil flow stops or the oil becomes severely
contaminated, failure can occur very quickly. Therefore, a fluid
particulate sensor or fluid pressure sensors may be an important
source of detection values.
[0783] In an illustrative and non-limiting example, fan integrity
may be evaluated by measuring air pulsations related to blade pass
frequencies. For example, if a fan has 12 blades, 12 air pulsations
may be measured. Variations in the amplitude of the pulsations
associated with the different blades may be indicative of changes
in a fan blade. Changes in frequencies associated with the air
pulsations may be indicative of bearing problems.
[0784] In an illustrative and non-limiting example, compressors
used in the gas and oil field or in gas handling equipment on an
assembly line may be evaluated by measuring the periodic increases
in energy/pressure in the storage vessel as gas is pumped into the
vessel. Periodic variations in the amplitude of the energy
increases may be associated with piston wear or damage to a portion
of a rotary screw. Phase evaluation of the energy signal relative
to timing signals may be helpful in identifying which piston or
portion of the rotary screw has damage. Changes in frequencies
associated with the energy pulsations may be indicative of bearing
problems.
[0785] In an illustrative and non-limiting example, cavitation/air
pockets in pumps may create shuttering in the pump housing and the
output flow which may be identified with the frequency
transformation and frequency analysis techniques described above
and elsewhere herein.
[0786] In an illustrative and non-limiting example, the frequency
transformation and frequency analysis techniques described above
and elsewhere herein may assist in the identification of problems
in components of building HVAC systems such as big fans. If the
dampers of the system are set poorly it may result in ducts pulsing
or vibrating as air is pushed through the system. Monitoring of
vibration sensors on the ducts may assist in the balancing of the
system. If there are defects in the blades of the big fan this may
also result in uneven air flow and resulting pulsation in the
buildings ductwork.
[0787] In an illustrative and non-limiting example, detection
values from acoustical sensors located close to the bearings may
assist in the identification of issues in the engagement between
gears or bad bearings. Based on a knowledge of gear ratios, such as
the "in" and "out" gear ratios, for a system and measurements of
the input and output rotational speed, detection values may be
evaluated for energy occurring at those ratios, which in turn may
be used to identify bad bearings. This could be done with simple
off the shelf motors rather than requiring extensive retrofitting
of the motor with sensors.
[0788] Based on the output of its various components, the signal
evaluation circuit 9208 may make a bearing life prediction,
identify a bearing health parameter, identify a bearing performance
parameter, determine a bearing health parameter (e.g., fault
conditions), and the like. The signal evaluation circuit 9208 may
identify wear on a bearing, identify the presence of foreign matter
(e.g., particulates) in the bearings, identify air gaps or a loss
of fluid in oil/fluid coated bearings, identify a loss of
lubrication in a set of bearings, identify a loss of power for
magnetic bearings and the like, identify strain/stress of flexure
bearings, and the like. The signal evaluation circuit 9208 may
identify optimal operation parameters for a piece of equipment to
extend bearing life. The signal evaluation circuit 9208 may
identify behavior (resonant wobble) at a selected operational
frequency (e.g., shaft rotation rate).
[0789] The signal evaluation circuit 9208 may communicate with the
data storage circuit 9216 to access equipment specifications,
equipment geometry, bearing specifications, bearing materials,
anticipated state information for a plurality of bearing types,
operational history, historical detection values, and the like for
use in assessing the output of its various components. The signal
evaluation circuit 9208 may buffer a subset of the plurality of
detection values, intermediate data such as time-based detection
values transformed to frequency information, filtered detection
values, identified frequencies of interest, and the like for a
predetermined length of time. The signal evaluation circuit 9208
may periodically store certain detection values in the data storage
circuit 9216 to enable the tracking of component performance over
time. In embodiments, based on relevant operating conditions and/or
failure modes that may occur as detection values approach one or
more criteria, the signal evaluation circuit 9208 may store data in
the data storage circuit 9216 based on the fit of data relative to
one or more criteria, such as those described throughout this
disclosure. Based on one sensor input meeting or approaching
specified criteria or range, the signal evaluation circuit 9208 may
store additional data such as RPMs, component loads, temperatures,
pressures, vibrations or other sensor data of the types described
throughout this disclosure in the data storage circuit 9216. The
signal evaluation circuit 9208 may store data at a higher data rate
for greater granularity in future processing, the ability to
reprocess at different sampling rates, and/or to enable diagnosing
or post-processing of system information where operational data of
interest is flagged, and the like.
[0790] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating and
the like, sensors 9206 may comprise one or more of, without
limitation, a vibration sensor, an optical vibration sensor, a
thermometer, a hygrometer, a voltage sensor, a current sensor, an
accelerometer, a velocity detector, a light or electromagnetic
sensor (e.g., determining temperature, composition and/or spectral
analysis, and/or object position or movement), an image sensor, a
structured light sensor, a laser-based image sensor, an infrared
sensor, an acoustic wave sensor, a heat flux sensor, a displacement
sensor, a turbidity meter, a viscosity meter, a load sensor, a
tri-axial vibration sensor, an accelerometer, a tachometer, a fluid
pressure meter, an air flow meter, a horsepower meter, a flow rate
meter, a fluid particle detector, an acoustical sensor, a pH
sensor, and the like, including, without limitation, any of the
sensors described throughout this disclosure and the documents
incorporated by reference. The sensors may typically comprise at
least a temperature sensor, a load sensor, a tri-axial sensor and a
tachometer.
[0791] The sensors 9206 may provide a stream of data over time that
has a phase component, such as relating to acceleration or
vibration, allowing for the evaluation of phase or frequency
analysis of different operational aspects of a piece of equipment
or an operating component. The sensors 9206 may provide a stream of
data that is not conventionally phase-based, such as temperature,
humidity, load, and the like. The sensors 9206 may provide a
continuous or near continuous stream of data over time, periodic
readings, event-driven readings, and/or readings according to a
selected interval or schedule.
[0792] In embodiments, as illustrated in FIG. 85, the sensors 9206
may be part of the data monitoring device 9200, referred to herein
in some cases as a data collector, which in some cases may comprise
a mobile or portable data collector. In embodiments, as illustrated
in FIGS. 86 and 87, one or more external sensors 9224, which are
not explicitly part of a monitoring device 9218 but rather are new,
previously attached to or integrated into the equipment or
component, may be opportunistically connected to or accessed by the
monitoring device 9218. The monitoring device 9218 may include a
controller 9220. The controller 9202 may include a data acquisition
circuit 9222, a data storage circuit 9216, a signal evaluation
circuit 9208 and, optionally, a response circuit 9210. The signal
evaluation circuit 9208 may comprise a frequency transformation
circuit 9212 and a frequency analysis circuit 9214. The data
acquisition circuit 9222 may include one or more input ports 9226.
The one or more external sensors 9224 may be directly connected to
the one or more input ports 9226 on the data acquisition circuit
9222 of the controller 9220 or may be accessed by the data
acquisition circuit 9222 wirelessly, such as by a reader,
interrogator, or other wireless connection, such as over a
short-distance wireless protocol. In embodiments as shown in FIG.
87, a data acquisition circuit 9222 may further comprise a wireless
communications circuit 9262. The data acquisition circuit 9222 may
use the wireless communications circuit 9262 to access detection
values corresponding to the one or more external sensors 9224
wirelessly or via a separate source or some combination of these
methods.
[0793] In embodiments, as illustrated in FIG. 88, the data
acquisition circuit 9222 may further comprise a multiplexer circuit
9236 as described elsewhere herein. Outputs from the multiplexer
circuit 9236 may be utilized by the signal evaluation circuit 9208.
The response circuit 9210 may have the ability to turn on and off
portions of the multiplexor circuit 9236. The response circuit 9210
may have the ability to control the control channels of the
multiplexor circuit 9236.
[0794] The response circuit 9210 may initiate actions based on a
bearing performance parameter, a bearing health value, a bearing
life prediction parameter, and the like. The response circuit 9210
may evaluate the results of the signal evaluation circuit 9208 and,
based on certain criteria or the output from various components of
the signal evaluation circuit 9208, initiate an action. The
criteria may include a sensor's detection values at certain
frequencies or phases relative to a timer signal where the
frequencies or phases of interest may be based on the equipment
geometry, equipment control schemes, system input, historical data,
current operating conditions, and/or an anticipated response. The
criteria may include a sensor's detection values at certain
frequencies or phases relative to detection values of a second
sensor. The criteria may include signal strength at certain
resonant frequencies/harmonics relative to detection values
associated with a system tachometer or anticipated based on
equipment geometry and operation conditions. Criteria may include a
predetermined peak value for a detection value from a specific
sensor, a cumulative value of a sensor's corresponding detection
value over time, a change in peak value, a rate of change in a peak
value, and/or an accumulated value (e.g., a time spent above/below
a threshold value, a weighted time spent above/below one or more
threshold values, and/or an area of the detected value above/below
one or more threshold values). The criteria may comprise
combinations of data from different sensors such as relative
values, relative changes in value, relative rates of change in
value, relative values over time, and the like. The relative
criteria may change with other data or information such as process
stage, type of product being processed, type of equipment, ambient
temperature and humidity, external vibrations from other equipment,
and the like. The relative criteria may be reflected in one or more
calculated statistics or metrics (including ones generated by
further calculations on multiple criteria or statistics), which in
turn may be used for processing (such as on-board a data collector
or by an external system), such as to be provided as an input to
one or more of the machine learning capabilities described in this
disclosure, to a control system (which may be on board a data
collector or remote, such as to control selection of data inputs,
multiplexing of sensor data, storage, or the like), or as a data
element that is an input to another system, such as a data stream
or data package that may be available to a data marketplace, a
SCADA system, a remote control system, a maintenance system, an
analytic system, or other system.
[0795] Certain embodiments are described herein as detected values
exceeding thresholds or predetermined values, but detected values
may also fall below thresholds or predetermined values--for
example, where an amount of change in the detected value is
expected to occur, but detected values indicate that the change may
not have occurred. For example, and without limitation, vibrational
data may indicate system agitation levels, properly operating
equipment, or the like, and vibrational data below amplitude and/or
frequency thresholds may be an indication of a process that is not
operating according to expectations. Except where the context
clearly indicates otherwise, any description herein describing a
determination of a value above a threshold and/or exceeding a
predetermined or expected value is understood to include
determination of a value below a threshold and/or falling below a
predetermined or expected value.
[0796] The predetermined acceptable range may be based on
anticipated system response or vibration based on the equipment
geometry and control scheme such as number of bearings, relative
rotational speed, influx of power to the system at a certain
frequency, and the like. The predetermined acceptable range may
also be based on long term analysis of detection values across a
plurality of similar equipment and components and correlation of
data with equipment failure.
[0797] In some embodiments, an alert may be issued based on some of
the criteria discussed above. In an illustrative example, an
increase in temperature and energy at certain frequencies may
indicate a hot bearing that is starting to fail. In embodiments,
the relative criteria for an alarm may change with other data or
information such as process stage, type of product being processed
on equipment, ambient temperature and humidity, external vibrations
from other equipment and the like. In an illustrative and
non-limiting example, the response circuit 9210 may initiate an
alert if a vibrational amplitude and/or frequency exceeds a
predetermined maximum value, if there is a change or rate of change
that exceeds a predetermined acceptable range, and/or if an
accumulated value based on vibrational amplitude and/or frequency
exceeds a threshold.
[0798] In embodiments, response circuit 9210 may cause the data
acquisition circuit 9204 to enable or disable the processing of
detection values corresponding to certain sensors based on some of
the criteria discussed above. This may include switching to sensors
having different response rates, sensitivity, ranges, and the like,
or accessing new sensors or types of sensors, and the like.
Switching may be undertaken based on a model, a set of rules, or
the like. In embodiments, switching may be under control of a
machine learning system, such that switching is controlled based on
one or more metrics of success, combined with input data, over a
set of trials, which may occur under supervision of a human
supervisor or under control of an automated system. Switching may
involve switching from one input port to another (such as to switch
from one sensor to another). Switching may involve altering the
multiplexing of data, such as combining different streams under
different circumstances. Switching may also involve activating a
system to obtain additional data, such as moving a mobile system
(such as a robotic or drone system), to a location where different
or additional data is available (such as positioning an image
sensor for a different view or positioning a sonar sensor for a
different direction of collection) or to a location where different
sensors can be accessed (such as moving a collector to connect up
to a sensor that is disposed at a location in an environment by a
wired or wireless connection). This switching may be implemented by
changing the control signals for a multiplexor circuit 9236 and/or
by turning on or off certain input sections of the multiplexor
circuit 9236. The response circuit 9210 may make recommendations
for the replacement of certain sensors in the future with sensors
having different response rates, sensitivity, ranges, and the like.
The response circuit 9210 may recommend design alterations for
future embodiments of the component, the piece of equipment, the
operating conditions, the process, and the like.
[0799] In embodiments, the response circuit 9210 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call. The response circuit 9210 may recommend changes in process or
operating parameters to remotely balance the piece of equipment. In
embodiments, the response circuit 9210 may implement or recommend
process changes--for example to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but still at least partially
operational, to change the operating speed of a component (such as
to put it in a lower-demand mode), to initiate amelioration of an
issue (such as to signal for additional lubrication of a roller
bearing set, or to signal for an alignment process for a system
that is out of balance), and the like.
[0800] In embodiments as shown in FIGS. 89, 90, 91, and 92, a data
monitoring system 9240 may include at least one data monitoring
device 9250. The at least one data monitoring device 9250 may
include sensors 9206 and a controller 9242 comprising a data
acquisition circuit 9204, a signal evaluation circuit 9208, a data
storage circuit 9216, and a communications circuit 9246. The signal
evaluation circuit 9208 may include at least one of a frequency
detection circuit 9212 and a frequency analysis circuit 9214. There
may also be an optional response circuit as described above and
elsewhere herein. The signal evaluation circuit 9208 may
periodically share data with the communication circuit 9246 for
transmittal to a remote server 9244 to enable the tracking of
component and equipment performance over time and under varying
conditions by a monitoring application 9248. Because relevant
operating conditions and/or failure modes may occur as sensor
values approach one or more criteria, the signal evaluation circuit
9208 may share data with the communication circuit 9246 for
transmittal to the remote server 9244 based on the fit of data
relative to one or more criteria. Based on one sensor input meeting
or approaching specified criteria or range, the signal evaluation
circuit 9208 may share additional data such as RPMs, component
loads, temperatures, pressures, vibrations, and the like for
transmittal. The signal evaluation circuit 9208 may share data at a
higher data rate for transmittal to enable greater granularity in
processing on the remote server.
[0801] In embodiments, as shown in FIG. 89, the communications
circuit 9246 may communicate data directly to a remote server 9244.
In embodiments, as shown in FIG. 90, the communications circuit
9246 may communicate data to an intermediate computer 9252, which
may include a processor 9254 running an operating system 9256 and a
data storage circuit 9258. The intermediate computer 9252 may
collect data from a plurality of data monitoring devices and send
the cumulative data to the remote server 9244.
[0802] In embodiments, as illustrated in FIGS. 91 and 92, a data
collection system 9260 may have a plurality of monitoring devices
9250 collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment, (both the same and different types of
equipment) in the same facility as well as collecting data from
monitoring devices in multiple facilities. A monitoring application
9248 on a remote server 9244 may receive and store one or more of
the following: detection values, timing signals and data coming
from a plurality of the various monitoring devices 9250. In
embodiments, as shown in FIG. 91, the communications circuit 9246
may communicate data directly to a remote server 9244. In
embodiments, as shown in FIG. 92, the communications circuit 9246
may communicate data to an intermediate computer 9252, which may
include a processor 9254 running an operating system 9256 and a
data storage circuit 9258. There may be an individual intermediate
computer 9252 associated with each monitoring device 9264 or an
individual intermediate computer 9252 may be associated with a
plurality of monitoring devices 9250 where the intermediate
computer 9252 may collect data from a plurality of data monitoring
devices and send the cumulative data to the remote server 9244.
[0803] The monitoring application 9248 may select subsets of the
detection values, timing signals and data to be jointly analyzed.
Subsets for analysis may be selected based on a bearing type,
bearing materials, or a single type of equipment in which a bearing
is operating. Subsets for analysis may be selected or grouped based
on common operating conditions or operational history such as size
of load, operational condition (e.g., intermittent, continuous),
operating speed or tachometer, common ambient environmental
conditions such as humidity, temperature, air or fluid particulate,
and the like. Subsets for analysis may be selected based on common
anticipated state information. Subsets for analysis may be selected
based on the effects of other nearby equipment such as nearby
machines rotating at similar frequencies, nearby equipment
producing electromagnetic fields, nearby equipment producing heat,
nearby equipment inducing movement or vibration, nearby equipment
emitting vapors, chemicals or particulates, or other potentially
interfering or intervening effects.
[0804] The monitoring application 9248 may analyze a selected
subset. In an illustrative example, data from a single component
may be analyzed over different time periods, such as one operating
cycle, cycle-to-cycle comparisons, trends over several operating
cycles/times such as a month, a year, the life of the component, or
the like. Data from multiple components of the same type may also
be analyzed over different time periods. Trends in the data such as
changes in frequency or amplitude may be correlated with failure
and maintenance records associated with the same component or piece
of equipment. Trends in the data such as changing rates of change
associated with start-up or different points in the process may be
identified. Additional data may be introduced into the analysis
such as output product quality, output quantity (such as per unit
of time), indicated success or failure of a process, and the like.
Correlation of trends and values for different types of data may be
analyzed to identify those parameters whose short-term analysis
might provide the best prediction regarding expected performance.
The analysis may identify model improvements to the model for
anticipated state information, recommendations around sensors to be
used, positioning of sensors and the like. The analysis may
identify additional data to collect and store. The analysis may
identify recommendations regarding needed maintenance and repair
and/or the scheduling of preventative maintenance. The analysis may
identify recommendations around purchasing replacement bearings and
the timing of the replacement of the bearings. The analysis may
result in warning regarding the dangers of catastrophic failure
conditions. This information may be transmitted back to the
monitoring device to update types of data collected and analyzed
locally or to influence the design of future monitoring
devices.
[0805] In embodiments, the monitoring application 9248 may have
access to equipment specifications, equipment geometry, bearing
specifications, bearing materials, anticipated state information
for a plurality of bearing types, operational history, historical
detection values, bearing life models and the like for use
analyzing the selected subset using rule-based or model-based
analysis. In embodiments, the monitoring application 9248 may feed
a neural net with the selected subset to learn to recognize various
operating state, health states (e.g., lifetime predictions) and
fault states utilizing deep learning techniques. In embodiments, a
hybrid of the two techniques (model-based learning and deep
learning) may be used.
[0806] In an illustrative and non-limiting example, the health of
bearings on conveyors and lifters in an assembly line, in water
pumps on industrial vehicles and in compressors in gas handling
systems, in compressors situated out in the gas and oil fields, in
factory air conditioning units and in factory mineral pumps may be
monitored using the frequency transformation and frequency analysis
techniques, data monitoring devices and data collection systems
described herein.
[0807] In an illustrative and non-limiting example, the health of
one or more of bearings, gears, blades, screws and associated
shafts, motors, rotors, stators, gears, and other components of
gear boxes, motors, pumps, vibrating conveyors, mixers,
centrifuges, drilling machines, screw drivers and refining tanks
situated in the oil and gas fields may be evaluated using the
frequency transformation and frequency analysis techniques, data
monitoring devices and data collection systems described
herein.
[0808] In an illustrative and non-limiting example, the health of
bearings and associated shafts, motors, rotors, stators, gears, and
other components of rotating tank/mixer agitators,
mechanical/rotating agitators, and propeller agitators, to promote
chemical reactions deployed in chemical and pharmaceutical
production lines may be evaluated using the frequency
transformation and frequency analysis techniques, data monitoring
devices and data collection systems described herein.
[0809] In an illustrative and non-limiting example, the health of
bearings and associated shafts, motors, rotors, stators, gears, and
other components of vehicle systems such as steering mechanisms or
engines may be evaluated using the frequency transformation and
frequency analysis techniques, data monitoring devices and data
collection systems described herein.
[0810] An example monitoring device for bearing analysis in an
industrial environment, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage for storing specifications and
anticipated state information for a plurality of bearing types and
buffering the plurality of detection values for a predetermined
length of time; and a bearing analysis circuit structured to
analyze buffered detection values relative to specifications and
anticipated state information resulting in a bearing performance
parameter.
[0811] In certain further embodiments, an example monitoring device
includes one or more of: a response circuit to perform at least one
operation in response to the bearing performance parameter, wherein
the plurality of input sensors includes at least two sensors
selected from the group consisting of a temperature sensor, a load
sensor, an optical vibration sensor, an acoustic wave sensor, a
heat flux sensor, an infrared sensor, an accelerometer, a tri-axial
vibration sensor and a tachometer; wherein the at least one
operation is further in response to at least one of: a change in
amplitude of at least one of the plurality of detection values; a
change in frequency or relative phase of at least one of the
plurality of detection values; a rate of change in both amplitude
and relative phase of at least one of the plurality of detection
values; and a relative rate of change in amplitude and relative
phase of at least one of the plurality of detection values; wherein
the at least one operation comprises issuing an alert; wherein the
alert may be one of haptic, audible and visual; wherein the at
least one operation further comprises storing additional data in
the data storage circuit; wherein the storing additional data in
the data storage circuit is further in response to at least one of:
a change in the relative phase difference and a relative rate of
change in the relative phase difference.
[0812] An example monitoring device for bearing analysis in an
industrial environment, the monitoring device includes: a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a data
storage for storing specifications and anticipated state
information for a plurality of bearing types and buffering the
plurality of detection values for a predetermined length of time;
and a bearing analysis circuit structured to analyze buffered
detection values relative to specifications and anticipated state
information resulting in a bearing health value.
[0813] In certain embodiments, an example monitoring device further
includes one or more of: a response circuit to perform at least one
operation in response to the bearing health value, wherein the
plurality of input sensors includes at least two sensors selected
from the group consisting of a temperature sensor, a load sensor,
an optical vibration sensor, an acoustic wave sensor, a heat flux
sensor, an infrared sensor, an accelerometer, a tri-axial vibration
sensor and a tachometer; wherein the at least one operation is
further in response to at least one of: a change in amplitude of at
least one of the plurality of detection values; a change in
frequency or relative phase of at least one of the plurality of
detection values; a rate of change in both amplitude and relative
phase of at least one of the plurality of detection values; and a
relative rate of change in amplitude and relative phase of at least
one of the plurality of detection values; wherein the at least one
operation comprises issuing an alert; wherein the alert may be one
of haptic, audible and visual; wherein the at least one operation
further comprises storing additional data in the data storage
circuit; wherein the storing additional data in the data storage
circuit is further in response to at least one of: a change in the
relative phase difference and a relative rate of change in the
relative phase difference.
[0814] An example monitoring device for bearing analysis in an
industrial environment, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage for storing specifications and
anticipated state information for a plurality of bearing types and
buffering the plurality of detection values for a predetermined
length of time; and a bearing analysis circuit structured to
analyze buffered detection values relative to specifications and
anticipated state information resulting in a bearing life
prediction parameter.
[0815] In certain embodiments, a monitoring device further includes
one or more of: a response circuit to perform at least one
operation in response to the bearing life prediction parameter,
wherein the plurality of input sensors includes at least two
sensors selected from the group consisting of a temperature sensor,
a load sensor, an optical vibration sensor, an acoustic wave
sensor, a heat flux sensor, an infrared sensor, an accelerometer, a
tri-axial vibration sensor and a tachometer; wherein the at least
one operation is further in response to at least one of: a change
in amplitude of at least one of the plurality of detection values;
a change in frequency or relative phase of at least one of the
plurality of detection values; a rate of change in both amplitude
and relative phase of at least one of the plurality of detection
values; and a relative rate of change in amplitude and relative
phase of at least one of the plurality of detection values; wherein
the at least one operation comprises issuing an alert; wherein the
alert may be one of haptic, audible and visual; wherein the at
least one operation further comprises storing additional data in
the data storage circuit; wherein the storing additional data in
the data storage circuit is further in response to at least one of:
a change in the relative phase difference and a relative rate of
change in the relative phase difference.
[0816] An example monitoring device for bearing analysis in an
industrial environment, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage for storing specifications and
anticipated state information for a plurality of bearing types and
buffering the plurality of detection values for a predetermined
length of time; and a bearing analysis circuit structured to
analyze buffered detection values relative to specifications and
anticipated state information resulting in a bearing performance
parameter, wherein the data acquisition circuit comprises a
multiplexer circuit whereby alternative combinations of the
detection values may be selected based on at least one of user
input, a detected state and a selected operating parameter for a
machine.
[0817] In certain further embodiments, an example monitoring device
further includes one or more of: a response circuit to perform at
least one operation in response to the bearing performance
parameter, wherein the plurality of input sensors includes at least
two sensors selected from the group consisting of a temperature
sensor, a load sensor, an optical vibration sensor, an acoustic
wave sensor, a heat flux sensor, an infrared sensor, an
accelerometer, a tri-axial vibration sensor and a tachometer; a
change in amplitude of at least one of the plurality of detection
values; a change in frequency or relative phase of at least one of
the plurality of detection values; a rate of change in both
amplitude and relative phase of at least one of the plurality of
detection values; and a relative rate of change in amplitude and
relative phase of at least one of the plurality of detection
values; wherein the at least one operation comprises issuing an
alert; wherein the alert may be one of haptic, audible and visual;
wherein the at least one operation further comprises storing
additional data in the data storage circuit; wherein the storing
additional data in the data storage circuit is further in response
to at least one of: a change in the relative phase difference and a
relative rate of change in the relative phase difference; wherein
the at least one operation comprises enabling or disabling one or
more portions of the multiplexer circuit, or altering the
multiplexer control lines; wherein the data acquisition circuit
comprises at least two multiplexer circuits and the at least one
operation comprises changing connections between the at least two
multiplexer circuits.
[0818] An example system for data collection, processing, and
bearing analysis in an industrial environment includes: a plurality
of monitoring devices, each monitoring device comprising: a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a data
storage for storing specifications and anticipated state
information for a plurality of bearing types and buffering the
plurality of detection values for a predetermined length of
time;
a bearing analysis circuit structured to analyze buffered detection
values relative to specifications and anticipated state information
resulting in a bearing life prediction; a communication circuit
structured to communicate with a remote server providing the
bearing life prediction and a portion of the buffered detection
values to the remote server; and a monitoring application on the
remote server structured to receive, store and jointly analyze a
subset of the detection values from the plurality of monitoring
devices.
[0819] In certain further embodiments, an example monitoring device
includes one or more of: a response circuit to perform at least one
operation in response to the bearing life prediction, wherein the
plurality of input sensors includes at least two sensors selected
from the group consisting of a temperature sensor, a load sensor,
an optical vibration sensor, an acoustic wave sensor, a heat flux
sensor, an infrared sensor, an accelerometer, a tri-axial vibration
sensor and a tachometer; wherein the at least one operation is
further in response to at least one of: a change in amplitude of at
least one of the plurality of detection values; a change in
frequency or relative phase of at least one of the plurality of
detection values; a rate of change in both amplitude and relative
phase of at least one of the plurality of detection values; and a
relative rate of change in amplitude and relative phase of at least
one of the plurality of detection values; wherein the at least one
operation comprises issuing an alert; wherein the alert may be one
of haptic, audible and visual; wherein the at least one operation
further comprises storing additional data in the data storage
circuit; wherein the storing additional data in the data storage
circuit is further in response to at least one of: a change in the
relative phase difference and a relative rate of change in the
relative phase difference.
[0820] An example system for data collection, processing, and
bearing analysis in an industrial environment comprising: a
plurality of monitoring devices, each comprising: a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a data
storage for storing specifications and anticipated state
information for a plurality of bearing types and buffering the
plurality of detection values for a predetermined length of time; a
bearing analysis circuit structured to analyze buffered detection
values relative to specifications and anticipated state information
resulting in a bearing performance parameter; a communication
circuit structured to communicate with a remote server providing
the life prediction and a portion of the buffered detection values
to the remote server; and a monitoring application on the remote
server structured to receive, store and jointly analyze a subset of
the detection values from the plurality of monitoring devices.
[0821] In certain further embodiments, an example monitoring device
further includes one or more of: a response circuit to perform at
least one operation in response to the bearing performance
parameter, wherein the plurality of input sensors includes at least
two sensors selected from the group consisting of a temperature
sensor, a load sensor, an optical vibration sensor, an acoustic
wave sensor, a heat flux sensor, an infrared sensor, an
accelerometer, a tri-axial vibration sensor and a tachometer;
wherein the at least one operation is further in response to at
least one of: a change in amplitude of at least one of the
plurality of detection values; a change in frequency or relative
phase of at least one of the plurality of detection values; a rate
of change in both amplitude and relative phase of at least one the
plurality of detection values; and a relative rate of change in
amplitude and relative phase of at least one the plurality of
detection values; wherein the at least one operation comprises
issuing an alert; wherein the alert may be one of haptic, audible
and visual; wherein the at least one operation further comprises
storing additional data in the data storage circuit; wherein
storing additional data in the data storage circuit is further in
response to at least one of: a change in the relative phase
difference and a relative rate of change in the relative phase
difference.
[0822] An example system for data collection, processing, and
bearing analysis in an industrial environment includes: a plurality
of monitoring devices, each monitoring device comprising: a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors
communicatively coupled to the data acquisition circuit; a
streaming circuit for streaming at least a subset of the acquired
detection values to a remote learning system; and a remote learning
system including a bearing analysis circuit structured to analyze
the detection values relative to a machine-based understanding of
the state of the at least one bearing.
[0823] In certain further embodiments, an example system further
includes one or more of: wherein the machine-based understanding is
developed based on a model of the bearing that determines a state
of the at least one bearing based at least in part on the
relationship of the behavior of the bearing to an operating
frequency of a component of the industrial machine; wherein the
state of the at least one bearing is at least one of an operating
state, a health state, a predicted lifetime state and a fault
state; wherein the machine-based understanding is developed based
by providing inputs to a deep learning machine, wherein the inputs
comprise a plurality of streams of detection values for a plurality
of bearings and a plurality of measured state values for the
plurality of bearings; wherein the state of the at least one
bearing is at least one of an operating state, a health state, a
predicted lifetime state and a fault state.
[0824] An example method of analyzing bearings and sets of
bearings, includes: receiving a plurality of detection values
corresponding to data from a temperature sensor, a vibration sensor
positioned near the bearing or set of bearings and a tachometer to
measure rotation of a shaft associated with the bearing or set of
bearings; comparing the detection values corresponding to the
temperature sensor to a predetermined maximum level; filtering the
detection values corresponding to the vibration sensor through a
high pass filter where the filter is selected to eliminate
vibrations associated with detection values associated with the
tachometer; identifying rapid changes in at least one of a
temperature peak and a vibration peak; identifying frequencies at
which spikes in the filtered detection values corresponding to the
vibration sensor occur and comparing frequencies and spikes in
amplitude relative to an anticipated state information and
specification associated with the bearing or set of bearings; and
determining a bearing health parameter.
[0825] An example device for monitoring roller bearings in an
industrial environment, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage circuit structured to store
specifications and anticipated state information for a plurality of
types of roller bearings and buffering the plurality of detection
values for a predetermined length of time; a bearing analysis
circuit structured to analyze buffered detection values relative to
specifications and anticipated state information resulting in a
bearing performance parameter; and a response circuit to perform at
least one operation in response to the bearing performance
prediction, wherein the plurality of input sensors includes at
least two sensors selected from the group consisting of a
temperature sensor, a load sensor, an optical vibration sensor, an
acoustic wave sensor, a heat flux sensor, an infrared sensor, an
accelerometer, a tri-axial vibration sensor and a tachometer.
[0826] An example device for monitoring sleeve bearings in an
industrial environment, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage for storing sleeve bearing
specifications and anticipated state information for types of
sleeve bearings and buffering the plurality of detection values for
a predetermined length of time; a bearing analysis circuit
structured to analyze buffered detection values relative to
specifications and anticipated state information resulting in a
bearing performance parameter; and a response circuit to perform at
least one operation in response to the bearing performance
parameter, wherein the plurality of input sensors includes at least
two sensors selected from the group consisting of a temperature
sensor, a load sensor, an optical vibration sensor, an acoustic
wave sensor, a heat flux sensor, an infrared sensor, an
accelerometer, a tri-axial vibration sensor and a tachometer.
[0827] An example system for monitoring pump bearings in an
industrial environment, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage for storing pump
specifications, bearing specifications, anticipated state
information for pump bearings and buffering the plurality of
detection values for a predetermined length of time; a bearing
analysis circuit structured to analyze buffered detection values
relative to specifications and anticipated state information
resulting in a bearing performance parameter; and a response
circuit to perform at least one operation in response to the
bearing performance parameter, wherein the plurality of input
sensors includes at least two sensors selected from the group
consisting of a temperature sensor, a load sensor, an optical
vibration sensor, an acoustic wave sensor, a heat flux sensor, an
infrared sensor, an accelerometer, a tri-axial vibration sensor and
a tachometer.
[0828] An example system for collection, processing, and analyzing
pump bearings in an industrial environment includes: a plurality of
monitoring devices, each comprising: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors communicatively coupled to the data
acquisition circuit; a data storage for storing pump
specifications, bearing specifications, anticipated state
information for pump bearings and buffering the plurality of
detection values for a predetermined length of time; a bearing
analysis circuit structured to analyze buffered detection values
relative to the pump and bearing specifications and anticipated
state information resulting in a bearing performance parameter; a
communication circuit structured to communicate with a remote
server providing the bearing performance parameter and a portion of
the buffered detection values to the remote server; and a
monitoring application on the remote server structured to receive,
store and jointly analyze a subset of the detection values from the
plurality of monitoring devices.
[0829] An example system for estimating a conveyor health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for the conveyor and associated rotating components, store
historical conveyor and component performance and buffer the
plurality of detection values for a predetermined length of time; a
bearing analysis circuit structured to analyze buffered detection
values relative to specifications and anticipated state information
resulting in a bearing performance parameter; and a system analysis
circuit structured to utilize the bearing performance and at least
one of an anticipated state, historical data and a system geometry
to estimate a conveyor health performance.
[0830] An example system for estimating an agitator health
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for the agitator and associated components, store historical
agitator and component performance and buffer the plurality of
detection values for a predetermined length of time; a bearing
analysis circuit structured to analyze buffered detection values
relative to specifications and anticipated state information
resulting in a bearing performance parameter; and a system analysis
circuit structured to utilize the bearing performance and at least
one of an anticipated state, historical data and a system geometry
to estimate an agitation health parameter. In certain further
embodiments, an example device further includes where the agitator
is one of a rotating tank mixer, a large tank mixer, a portable
tank mixers, a tote tank mixer, a drum mixer, a mounted mixer and a
propeller mixer.
[0831] An example system for estimating a vehicle steering system
performance parameter, includes: a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
a plurality of input sensors, wherein the plurality of input
sensors comprises at least one of an angular position sensor, an
angular velocity sensor and an angular acceleration sensor
positioned to measure the rotating component; a data storage
circuit structured to store specifications, system geometry, and
anticipated state information for the vehicle steering system, the
rack, the pinion, and the steering column, store historical
steering system performance and buffer the plurality of detection
values for a predetermined length of time; a bearing analysis
circuit structured to analyze buffered detection values relative to
specifications and anticipated state information resulting in a
bearing performance parameter; and a system analysis circuit
structured to utilize the bearing performance and at least one of
an anticipated state, historical data and a system geometry to
estimate a vehicle steering system performance parameter.
[0832] An example system for estimating a pump performance
parameter, includes: a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for the pump and pump components, store historical steering system
performance and buffer the plurality of detection values for a
predetermined length of time; a bearing analysis circuit structured
to analyze buffered detection values relative to specifications and
anticipated state information resulting in a bearing performance
parameter; a system analysis circuit structured to utilize the
bearing performance and at least one of an anticipated state,
historical data and a system geometry to estimate a pump
performance parameter. In certain embodiments, and example system
further includes wherein the pump is a water pump in a car, and/or
wherein the pump is a mineral pump.
[0833] An example system for estimating a performance parameter for
a drilling machine, includes: a data acquisition circuit structured
to interpret a plurality of detection values, each of the plurality
of detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for the drilling machine and drilling machine components, store
historical drilling machine performance and buffer the plurality of
detection values for a predetermined length of time; a bearing
analysis circuit structured to analyze buffered detection values
relative to specifications and anticipated state information
resulting in a bearing performance parameter; and a system analysis
circuit structured to utilize the bearing performance and at least
one of an anticipated state, historical data and a system geometry
to estimate a performance parameter for the drilling machine. In
certain further embodiments, the drilling machine is one of an oil
drilling machine and a gas drilling machine.
[0834] An example system for estimating a performance parameter for
a drilling machine, includes: a data acquisition circuit structured
to interpret a plurality of detection values, each of the plurality
of detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for the drilling machine and drilling machine components, store
historical drilling machine performance and buffer the plurality of
detection values for a predetermined length of time; a bearing
analysis circuit structured to analyze buffered detection values
relative to specifications and anticipated state information
resulting in a bearing performance parameter; and a system analysis
circuit structured to utilize bearing performance and at least one
of an anticipated state, historical data and a system geometry to
estimate a performance parameter for the drilling machine.
[0835] Rotating components are used throughout many different types
of equipment and applications. Rotating components may include
shafts, motors, rotors, stators, bearings, fins, vanes, wings,
blades, fans, bearings, wheels, hubs, spokes, balls, rollers, pins,
gears and the like. In embodiments, information about the health or
other status or state information of or regarding a rotating
component in a piece of industrial equipment or in an industrial
process may be obtained by monitoring the condition of the
component or various other components of the industrial equipment
or industrial process and identifying torsion on the component.
Monitoring may include monitoring the amplitude and phase of a
sensor signal, such as one measuring attributes such as angular
position, angular velocity, angular acceleration, and the like.
[0836] An embodiment of a data monitoring device 9400 is shown in
FIG. 93 and may include a plurality of sensors 9406 communicatively
coupled to a controller 9402. The controller 9402 may include a
data acquisition circuit 9404, a data storage circuit 9414, a
system evaluation circuit 9408 and, optionally, a response circuit
9410. The system evaluation circuit 9408 may comprise a torsion
analysis circuit 9412.
[0837] The plurality of sensors 9406 may be wired to ports on the
data acquisition circuit 9404. The plurality of sensors 9406 may be
wirelessly connected to the data acquisition circuit 9404. The data
acquisition circuit 9404 may be able to access detection values
corresponding to the output of at least one of the plurality of
sensors 9406 where the sensors 9406 may be capturing data on
different operational aspects of a bearing or piece of equipment or
infrastructure.
[0838] The selection of the plurality of sensors 9406 for a data
monitoring device 9400 designed to assess torsion on a component,
such as a shaft, motor, rotor, stator, bearing or gear, or other
component described herein, or a combination of components, such as
within or comprising a drive train or piece of equipment or system,
may depend on a variety of considerations such as accessibility for
installing new sensors, incorporation of sensors in the initial
design, anticipated operational and failure conditions, reliability
of the sensors, and the like. The impact of failure may drive the
extent to which a bearing or piece of equipment is monitored with
more sensors and/or higher capability sensors being dedicated to
systems where unexpected or undetected bearing failure would be
costly or have severe consequences. To assess torsion the sensors
may include, among other options, an angular position sensor and/or
an angular velocity sensor and/or an angular acceleration
sensor.
[0839] The system evaluation circuit 9408 may process the detection
values to obtain information about one or more rotating components
being monitored. The torsional analysis circuit 9412 may be
structured to identify torsion in a component or system, such as
based on anticipated state, historical state, system geometry and
the like, such as that which is available from the data storage
circuit 9414. The torsional analysis circuit 9412 may be structured
to identify torsion using a variety of techniques such as
amplitude, phase and frequency differences in the detection values
from two linear accelerometers positioned at different locations on
a shaft. The torsional analysis circuit 9412 may identify torsion
using the difference in amplitude and phase between an angular
accelerometer on a shaft and an angular accelerometer on a slip
ring on the end of the shaft. The torsional analysis circuit 9412
may identify shear stress/elongation on a component using two
strain gauges in a half bridge configuration or four strain gauges
in a full bridge configuration. The torsional analysis circuit 9412
may use coder based techniques such as markers to identify the
rotation of a shaft, bearing, rotor, stator, gear or other rotating
component. The markers being assessed may include visual markers
such as gear teeth or stripes on a shaft captured by an image
sensor, light detector or the like. The markers being assessed may
include magnetic components located on the rotating component and
sensed by an electromagnetic pickup. The sensor may be a Hall
Effect sensor.
[0840] Additional input sensors may include a thermometer, a heat
flux sensor, a magnetometer, an axial load sensor, a radial load
sensor, an accelerometer, a shear-stress torque sensor, a twist
angle sensor and the like. Twist angle may include rotational
information at two positions on shaft or an angular velocity or
angular acceleration at two positions on a shaft. In embodiments,
the sensors may be positioned at different ends of the shaft.
[0841] The torsional analysis circuit 9412 may include one or more
of a transient signal analysis circuit and/or a frequency
transformation circuit and/or a frequency analysis circuit as
described elsewhere herein.
[0842] In embodiments, the transitory signal analysis circuit for
torsional analysis may include envelope modulation analysis, and
other transitory signal analysis techniques. The system evaluation
circuit 9408 may store long stream of detection values to the data
storage circuit 9414. The transitory signal analysis circuit may
use envelope analysis techniques on those long streams of detection
values to identify transient effects (such as impacts) which may
not be identified by conventional sine wave analysis (such as
FFTs).
[0843] In embodiments, the frequencies of interest may include
identifying energy at relation-order bandwidths for rotating
equipment. The maximum order observed may comprise a function of
the bandwidth of the system and the rotational speed of the
component. For varying speeds (run-ups, run-downs, etc.), the
minimum RPM may determine the maximum-observed order. In
embodiments, there may be torsional resonance at harmonics of the
forcing frequency/frequency at which a component is being
driven.
[0844] In an illustrative and non-limiting example, the monitoring
device may be used to collect and process sensor data to measure
torsion on a component. The monitoring device may be in
communication with or include a high resolution, high speed
vibration sensor to collect data over an extended period of time,
enough to measure multiple cycles of rotation. For gear driven
equipment, the sampling resolution should be such that the number
of samples taken per cycle is at least equal to the number of gear
teeth driving the component. It will be understood that a lower
sampling resolution may also be utilized, which may result in a
lower confidence determination and/or taking data over a longer
period of time to develop sufficient statistical confidence. This
data may then be used in the generation of a phase reference
(relative probe) or tachometer signal for a piece of equipment.
This phase reference may be used to align phase data such as
velocity and/or positional and/or acceleration data from multiple
sensors located at different positions on a component or on
different components within a system. This information may
facilitate the determination of torsion for different components or
the generation of an Operational Deflection Shape ("ODS"),
indicating the extent of torsion on one or more components during
an operational mode.
[0845] The higher resolution data stream may provide additional
data for the detection of transitory signals in low speed
operations. The identification of transitory signals may enable the
identification of defects in a piece of equipment or component.
[0846] In an illustrative and non-limiting example, the monitoring
device may be used to identify mechanical jitter for use in failure
prediction models. The monitoring device may begin acquiring data
when the piece of equipment starts up through ramping up to
operating speed or during operation. Once at operating speed, it is
anticipated that the torsional jitter should be minimal and changes
in torsion during this phase may be indicative of cracks, bearing
faults and the like. Additionally, known torsions may be removed
from the signal to facilitate the identification of unanticipated
torsions resulting from system design flaws or component wear.
Having phase information associated with the data collected at
operating speed may facilitate identification of a location of
vibration and potential component wear. Relative phase information
for a plurality of sensors located throughout a machine may
facilitate the evaluation of torsion as it is propagated through a
piece of equipment.
[0847] Based on the output of its various components, the system
evaluation circuit 9408 may make a component life prediction,
identify a component health parameter, identify a component
performance parameter, and the like. The system evaluation circuit
9408 may identify unexpected torsion on a rotating component,
identify strain/stress of flexure bearings, and the like. The
system evaluation circuit 9408 may identify optimal operation
parameters for a piece of equipment to reduce torsion and extend
component life. The system evaluation circuit 9408 may identify
torsion at selected operational frequencies (e.g., shaft rotation
rates). Information about operational frequencies causing torsion
may facilitate equipment operational balance in the future.
[0848] The system evaluation circuit 9408 may communicate with the
data storage circuit 9414 to access equipment specifications,
equipment geometry, bearing specifications, component materials,
anticipated state information for a plurality of component types,
operational history, historical detection values, and the like for
use in assessing the output of its various components. The system
evaluation circuit 9408 may buffer a subset of the plurality of
detection values, intermediate data such as time-based detection
values, time-based detection values transformed to frequency
information, filtered detection values, identified frequencies of
interest, and the like for a predetermined length of time. The
system evaluation circuit 9408 may periodically store certain
detection values in the data storage circuit 9414 to enable the
tracking of component performance over time. In embodiments, based
on relevant operating conditions and/or failure modes, which may
occur as detection values approach one or more criteria, the system
evaluation circuit 9408 may store data in the data storage circuit
9414 based on the fit of data relative to one or more criteria,
such as those described throughout this disclosure. Based on one
sensor input meeting or approaching specified criteria or range,
the system evaluation circuit 9408 may store additional data such
as RPM information, component loads, temperatures, pressures,
vibrations or other sensor data of the types described throughout
this disclosure in the data storage circuit 9414. The system
evaluation circuit 9408 may store data in the data storage circuit
at a higher data rate for greater granularity in future processing,
the ability to reprocess at different sampling rates, and/or to
enable diagnosing or post-processing of system information where
operational data of interest is flagged, and the like.
[0849] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating and
the like, sensors 9406 may comprise, without limitation, one or
more of the following: a displacement sensor, an angular velocity
sensor, an angular accelerometer, a vibration sensor, an optical
vibration sensor, a thermometer, a hygrometer, a voltage sensor, a
current sensor, an accelerometer, a velocity detector, a light or
electromagnetic sensor (e.g., determining temperature, composition
and/or spectral analysis, and/or object position or movement), an
image sensor, a structured light sensor, a laser-based image
sensor, an infrared sensor, an acoustic wave sensor, a heat flux
sensor, a displacement sensor, a turbidity meter, a viscosity
meter, a load sensor, a tri-axial vibration sensor, an
accelerometer, a tachometer, a fluid pressure meter, an air flow
meter, a horsepower meter, a flow rate meter, a fluid particle
detector, an acoustical sensor, a pH sensor, and the like,
including, without limitation, any of the sensors described
throughout this disclosure and the documents incorporated by
reference.
[0850] The sensors 9406 may provide a stream of data over time that
has a phase component, such as relating to angular velocity,
angular acceleration or vibration, allowing for the evaluation of
phase or frequency analysis of different operational aspects of a
piece of equipment or an operating component. The sensors 9406 may
provide a stream of data that is not conventionally phase-based,
such as temperature, humidity, load, and the like. The sensors 9406
may provide a continuous or near continuous stream of data over
time, periodic readings, event-driven readings, and/or readings
according to a selected interval or schedule.
[0851] In an illustrative and non-limiting example, when assessing
engine components it may be desirable to remove vibrations due to
the timing of piston vibrations or anticipated vibrational input
due to crankshaft geometry to assist in identifying other torsional
forces on a component. This may assist in assessing the health of
such diverse components as a water pump in a vehicle or positive
displacement pumps.
[0852] In an illustrative and non-limiting example, torsional
analysis and the identification of variations in torsion may assist
in the identification of stick-slip in a gear or transfer system.
In some cases, this may only occur once per cycle, and phase
information may be as important as or more important than the
amplitude of the signal in determining system state or
behavior.
[0853] In an illustrative and non-limiting example, torsional
analysis may assist in the identification, prediction (e.g.,
timing) and evaluation of lash in a drive train and the follow-on
torsion resulting from a change in direction or start up, which in
turn may be used for controlling a system, assessing needs for
maintenance, assessing needs for balancing or otherwise re-setting
components, or the like.
[0854] In an illustrative and non-limiting example, when assessing
compressors, it may be desirable to remove vibrations due to the
timing of piston vibrations or anticipated vibrational input
associated with the techniques and geometry used for positive
displacement compressors to assist in identifying other torsional
forces on a component. This may assist in assessing the health of
compressors in such diverse environments as air conditioning units
in factories, compressors in gas handling systems in an industrial
environment, compressors in oil fields, and other environments as
described elsewhere herein.
[0855] In an illustrative and non-limiting example, torsional
analysis may facilitate the understanding of the health and
expected life of various components associated with the drive
trains of vehicles, such as cranes, bulldozers, tractors, haulers,
backhoes, forklifts, agricultural equipment, mining equipment,
boring and drilling machines, digging machines, lifting machines,
mixers (e.g., cement mixers), tank trucks, refrigeration trucks,
security vehicles (e.g., including safes and similar facilities for
preserving valuables), underwater vehicles, watercraft, aircraft,
automobiles, trucks, trains and the like, as well as drive trains
of moving apparatus, such as assembly lines, lifts, cranes,
conveyors, hauling systems, and others. The evaluation of the
sensor data with the model of the system geometry and operating
conditions may be useful in identifying unexpected torsion and the
transmission of that torsion from the motor and drive shaft, from
the drive shaft to the universal joint and from the universal joint
to one or more wheel axles.
[0856] In an illustrative and non-limiting example, torsional
analysis may facilitate in the understanding of the health and
expected life of various components associated with train/tram
wheels and wheel sets. As discussed above, torsional analysis may
facilitate in the identification of stick-slip between the wheels
or wheel sets and the rail. The torsional analysis in view of the
system geometry may facilitate the identification of torsional
vibration due to stick-slip as opposed to the torsional vibration
due to the driving geometry connecting the engine to the drive
shaft to the wheel axle.
[0857] In embodiments, as illustrated in FIG. 93, the sensors 9406
may be part of the data monitoring device 9400, referred to herein
in some cases as a data collector, which in some cases may comprise
a mobile or portable data collector. In embodiments, as illustrated
in FIGS. 94 and 95, one or more external sensors 9422, which are
not explicitly part of a monitoring device 9416 but rather are new,
previously attached to or integrated into the equipment or
component, may be opportunistically connected to or accessed by the
monitoring device 9416. The monitoring device 9416 may include a
controller 9418. The controller 9418 may include a data acquisition
circuit 9420, a data storage circuit 9414, a system evaluation
circuit 9408 and, optionally, a response circuit 9410. The system
evaluation circuit 9408 may comprise a torsional analysis circuit
9412. The data acquisition circuit 9420 may include one or more
input ports 9424. In embodiments as shown in FIG. 95, a data
acquisition circuit 9420 may further comprise a wireless
communications circuit 9426. The one or more external sensors 9422
may be directly connected to the one or more input ports 9424 on
the data acquisition circuit 9420 of the controller 9418 or may be
accessed by the data acquisition circuit 9420 wirelessly using the
wireless communications circuit 9426, such as by a reader,
interrogator, or other wireless connection, such as over a
short-distance wireless protocol. The data acquisition circuit 9420
may use the wireless communications circuit 9426 to access
detection values corresponding to the one or more external sensors
9422 wirelessly or via a separate source or some combination of
these methods.
[0858] In embodiments, as illustrated in FIG. 96, the data
acquisition circuit 9432 may further comprise a multiplexer circuit
9434 as described elsewhere herein. Outputs from the multiplexer
circuit 9434 may be utilized by the system evaluation circuit 9408.
The response circuit 9410 may have the ability to turn on or off
portions of the multiplexor circuit 9434. The response circuit 9410
may have the ability to control the control channels of the
multiplexor circuit 9434
[0859] The response circuit 9410 may initiate actions based on a
component performance parameter, a component health value, a
component life prediction parameter, and the like. The response
circuit 9410 may evaluate the results of the system evaluation
circuit 9408 and, based on certain criteria or the output from
various components of the system evaluation circuit 9408, may
initiate an action. The criteria may include identification of
torsion on a component by the torsional analysis circuit. The
criteria may include a sensor's detection values at certain
frequencies or phases relative to a timer signal where the
frequencies or phases of interest may be based on the equipment
geometry, equipment control schemes, system input, historical data,
current operating conditions, and/or an anticipated response. The
criteria may include a sensor's detection values at certain
frequencies or phases relative to detection values of a second
sensor. The criteria may include signal strength at certain
resonant frequencies/harmonics relative to detection values
associated with a system tachometer or anticipated based on
equipment geometry and operation conditions. Criteria may include a
predetermined peak value for a detection value from a specific
sensor, a cumulative value of a sensor's corresponding detection
value over time, a change in peak value, a rate of change in a peak
value, and/or an accumulated value (e.g., a time spent above/below
a threshold value, a weighted time spent above/below one or more
threshold values, and/or an area of the detected value above/below
one or more threshold values). The criteria may comprise
combinations of data from different sensors such as relative
values, relative changes in value, relative rates of change in
value, relative values over time, and the like. The relative
criteria may change with other data or information such as process
stage, type of product being processed, type of equipment, ambient
temperature and humidity, external vibrations from other equipment,
and the like. The relative criteria may be reflected in one or more
calculated statistics or metrics (including ones generated by
further calculations on multiple criteria or statistics), which in
turn may be used for processing (such as on board a data collector
or by an external system), such as to be provided as an input to
one or more of the machine learning capabilities described in this
disclosure, to a control system (which may be on board a data
collector or remote, such as to control selection of data inputs,
multiplexing of sensor data, storage, or the like), or as a data
element that is an input to another system, such as a data stream
or data package that may be available to a data marketplace, a
SCADA system, a remote control system, a maintenance system, an
analytic system, or other system.
[0860] Certain embodiments are described herein as detected values
exceeding thresholds or predetermined values, but detected values
may also fall below thresholds or predetermined values--for example
where an amount of change in the detected value is expected to
occur, but detected values indicate that the change may not have
occurred. Except where the context clearly indicates otherwise, any
description herein describing a determination of a value above a
threshold and/or exceeding a predetermined or expected value is
understood to include determination of a value below a threshold
and/or falling below a predetermined or expected value.
[0861] The predetermined acceptable range may be based on
anticipated torsion based on equipment geometry, the geometry of a
transfer system, an equipment configuration or control scheme, such
as a piston firing sequence, and the like. The predetermined
acceptable range may also be based on historical performance or
predicted performance, such as long term analysis of signals and
performance both from the past run and from the past several runs.
The predetermined acceptable range may also be based on historical
performance or predicted performance, or based on long term
analysis of signals and performance across a plurality of similar
equipment and components (both within a specific environment,
within an individual company, within multiple companies in the same
industry and across industries). The predetermined acceptable range
may also be based on a correlation of sensor data with actual
equipment and component performance.
[0862] In some embodiments, an alert may be issued based on some of
the criteria discussed above. In embodiments, the relative criteria
for an alarm may change with other data or information, such as
process stage, type of product being processed on equipment,
ambient temperature and humidity, external vibrations from other
equipment and the like. In an illustrative and non-limiting
example, the response circuit 9410 may initiate an alert if a
torsion in a component across a plurality of components exceeds a
predetermined maximum value, if there is a change or rate of change
that exceeds a predetermined acceptable range, and/or if an
accumulated value based on torsion amplitude and/or frequency
exceeds a threshold.
[0863] In embodiments, response circuit 9410 may cause the data
acquisition circuit 9432 to enable or disable the processing of
detection values corresponding to certain sensors based on some of
the criteria discussed above. This may include switching to sensors
having different response rates, sensitivity, ranges, and the like;
accessing new sensors or types of sensors, and the like. Switching
may be undertaken based on a model, a set of rules, or the like. In
embodiments, switching may be under control of a machine learning
system, such that switching is controlled based on one or more
metrics of success, combined with input data, over a set of trials,
which may occur under supervision of a human supervisor or under
control of an automated system. Switching may involve switching
from one input port to another (such as to switch from one sensor
to another). Switching may involve altering the multiplexing of
data, such as combining different streams under different
circumstances. Switching may involve activating a system to obtain
additional data, such as moving a mobile system (such as a robotic
or drone system), to a location where different or additional data
is available (such as positioning an image sensor for a different
view or positioning a sonar sensor for a different direction of
collection) or to a location where different sensors can be
accessed (such as moving a collector to connect up to a sensor that
is disposed at a location in an environment by a wired or wireless
connection). This switching may be implemented by changing the
control signals for a multiplexor circuit 9434 and/or by turning on
or off certain input sections of the multiplexor circuit 9434.
[0864] The response circuit 9410 may calculate transmission
effectiveness based on differences between a measured and
theoretical angular position and velocity of an output shaft after
accounting for the gear ration and any phase differential between
input and output.
[0865] The response circuit 9410 may identify equipment or
components that are due for maintenance. The response circuit 9410
may make recommendations for the replacement of certain sensors in
the future with sensors having different response rates,
sensitivity, ranges, and the like. The response circuit 9410 may
recommend design alterations for future embodiments of the
component, the piece of equipment, the operating conditions, the
process, and the like.
[0866] In embodiments, the response circuit 9410 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call. The response circuit 9410 may recommend changes in process or
operating parameters to remotely balance the piece of equipment. In
embodiments, the response circuit 9410 may implement or recommend
process changes--for example to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but still at least partially
operational, to change the operating speed of a component (such as
to put it in a lower-demand mode), to initiate amelioration of an
issue (such as to signal for additional lubrication of a roller
bearing set, or to signal for an alignment process for a system
that is out of balance), and the like.
[0867] In embodiments as shown in FIGS. 97, 98, 99, and 100, a data
monitoring system 9460 may include at least one data monitoring
device 9448. At least one data monitoring device 9448 may include
sensors 9406 and a controller 9438 comprising a data acquisition
circuit 9404, a system evaluation circuit 9408, a data storage
circuit 9414, and a communications circuit 9442. The system
evaluation circuit 9408 may include a torsional analysis circuit
9412. There may also be an optional response circuit as described
above and elsewhere herein. The system evaluation circuit 9408 may
periodically share data with the communication circuit 9442 for
transmittal to the remote server 9440 to enable the tracking of
component and equipment performance over time and under varying
conditions by a monitoring application 9446. Because relevant
operating conditions and/or failure modes may occur as sensor
values approach one or more criteria, the system evaluation circuit
9408 may share data with the communication circuit 9462 for
transmittal to the remote server 9440 based on the fit of data
relative to one or more criteria. Based on one sensor input meeting
or approaching specified criteria or range, the system evaluation
circuit 9408 may share additional data such as RPMs, component
loads, temperatures, pressures, vibrations, and the like for
transmittal. The system evaluation circuit 9408 may share data at a
higher data rate for transmittal to enable greater granularity in
processing on the remote server. In embodiments, as shown in FIG.
97, the communications circuit 9442 may communicate data directly
to a remote server 9440. In embodiments, as shown in FIG. 98, the
communications circuit 9442 may communicate data to an intermediate
computer 9450 which may include a processor 9452 running an
operating system 9454 and a data storage circuit 9456.
[0868] In embodiments, as illustrated in FIGS. 99 and 100, a data
collection system 9458 may have a plurality of monitoring devices
9448 collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment (both the same and different types of
equipment) in the same facility as well as collecting data from
monitoring devices in multiple facilities. A monitoring application
9446 on a remote server 9440 may receive and store one or more of
detection values, timing signals and data coming from a plurality
of the various monitoring devices 9448. In embodiments, as shown in
FIG. 99, the communications circuit 9442 may communicate data
directly to a remote server 9440. In embodiments, as shown in FIG.
100, the communications circuit 9442 may communicate data to an
intermediate computer 9450, which may include a processor 9452
running an operating system 9454 and a data storage circuit 9456.
There may be an individual intermediate computer 9450 associated
with each monitoring device 9264 or an individual intermediate
computer 9450 may be associated with a plurality of monitoring
devices 9448 where the intermediate computer 9450 may collect data
from a plurality of data monitoring devices and send the cumulative
data to the remote server 9440.
[0869] The monitoring application 9446 may select subsets of
detection values, timing signals, data, product performance and the
like to be jointly analyzed. Subsets for analysis may be selected
based on component type, component materials, or a single type of
equipment in which a component is operating. Subsets for analysis
may be selected or grouped based on common operating conditions or
operational history such as size of load, operational condition
(e.g., intermittent, continuous), operating speed or tachometer,
common ambient environmental conditions such as humidity,
temperature, air or fluid particulate, and the like. Subsets for
analysis may be selected based on common anticipated state
information. Subsets for analysis may be selected based on the
effects of other nearby equipment such as nearby machines rotating
at similar frequencies, nearby equipment producing electromagnetic
fields, nearby equipment producing heat, nearby equipment inducing
movement or vibration, nearby equipment emitting vapors, chemicals
or particulates, or other potentially interfering or intervening
effects.
[0870] The monitoring application 9446 may analyze a selected
subset. In an illustrative example, data from a single component
may be analyzed over different time periods such as one operating
cycle, cycle to cycle comparisons, trends over several operating
cycles/time such as a month, a year, the life of the component or
the like. Data from multiple components of the same type may also
be analyzed over different time periods. Trends in the data such as
changes in frequency or amplitude may be correlated with failure
and maintenance records associated with the same component or piece
of equipment. Trends in the data such as changing rates of change
associated with start-up or different points in the process may be
identified. Additional data may be introduced into the analysis
such as output product quality, output quantity (such as per unit
of time), indicated success or failure of a process, and the like.
Correlation of trends and values for different types of data may be
analyzed to identify those parameters whose short-term analysis
might provide the best prediction regarding expected performance.
The analysis may identify model improvements to the model for
anticipated state information, recommendations around sensors to be
used, positioning of sensors and the like. The analysis may
identify additional data to collect and store. The analysis may
identify recommendations regarding needed maintenance and repair
and/or the scheduling of preventative maintenance. The analysis may
identify recommendations around purchasing replacement components
and the timing of the replacement of the components. The analysis
may identify recommendations regarding future geometry changes to
reduce torsion on components. The analysis may result in warning
regarding dangers of catastrophic failure conditions. This
information may be transmitted back to the monitoring device to
update types of data collected and analyzed locally or to influence
the design of future monitoring devices.
[0871] In embodiments, the monitoring application 9446 may have
access to equipment specifications, equipment geometry, component
specifications, component materials, anticipated state information
for a plurality of component types, operational history, historical
detection values, component life models and the like for use
analyzing the selected subset using rule-based or model-based
analysis. In embodiments, the monitoring application 9446 may feed
a neural net with the selected subset to learn to recognize various
operating states, health states (e.g., lifetime predictions) and
fault states utilizing deep learning techniques. In embodiments, a
hybrid of the two techniques (model-based learning and deep
learning) may be used.
[0872] In an illustrative and non-limiting example, the health of
the rotating components on conveyors and lifters in an assembly
line may be monitored using the torsional analysis techniques, data
monitoring devices and data collection systems described
herein.
[0873] In an illustrative and non-limiting example, the health the
rotating components in water pumps on industrial vehicles may be
monitored using the torsional analysis techniques, data monitoring
devices and data collection systems described herein.
[0874] In an illustrative and non-limiting example, the health of
rotating components in compressors in gas handling systems may be
monitored using the data monitoring devices and data collection
systems described herein.
[0875] In an illustrative and non-limiting example, the health of
the rotating components in compressors situated in the gas and oil
fields may be monitored using the data monitoring devices and data
collection systems described herein.
[0876] In an illustrative and non-limiting example, the health of
the rotating components in factory air conditioning units may be
evaluated using the techniques, data monitoring devices and data
collection systems described herein.
[0877] In an illustrative and non-limiting example, the health of
the rotating components in factory mineral pumps may be evaluated
using the techniques, data monitoring devices and data collection
systems described herein.
[0878] In an illustrative and non-limiting example, the health of
the rotating components such as shafts, bearings, and gears in
drilling machines and screw drivers situated in the oil and gas
fields may be evaluated using the torsional analysis techniques,
data monitoring devices and data collection systems described
herein.
[0879] In an illustrative and non-limiting example, the health of
rotating components such as shafts, bearings, gears, and rotors of
motors situated in the oil and gas fields may be evaluated using
the torsional analysis techniques, data monitoring devices and data
collection systems described herein.
[0880] In an illustrative and non-limiting example, the health of
rotating components such as blades, screws and other components of
pumps situated in the oil and gas fields may be evaluated using the
torsional analysis techniques, data monitoring devices and data
collection systems described herein.
[0881] In an illustrative and non-limiting example, the health of
rotating components such as shafts, bearings, motors, rotors,
stators, gears, and other components of vibrating conveyors
situated in the oil and gas fields may be evaluated using the
torsional analysis techniques, data monitoring devices and data
collection systems described herein.
[0882] In an illustrative and non-limiting example, the health of
rotating components such as bearings, shafts, motors, rotors,
stators, gears, and other components of mixers situated in the oil
and gas fields may be evaluated using the torsional analysis
techniques, data monitoring devices and data collection systems
described herein.
[0883] In an illustrative and non-limiting example, the health of
rotating components such as bearings, shafts, motors, rotors,
stators, gears, and other components of centrifuges situated in oil
and gas refineries may be evaluated using the torsional analysis
techniques, data monitoring devices and data collection systems
described herein.
[0884] In an illustrative and non-limiting example, the health of
rotating components such as bearings, shafts, motors, rotors,
stators, gears, and other components of refining tanks situated in
oil and gas refineries may be evaluated using the torsional
analysis techniques, data monitoring devices and data collection
systems described herein.
[0885] In an illustrative and non-limiting example, the health of
rotating components such as bearings, shafts, motors, rotors,
stators, gears, and other components of rotating tank/mixer
agitators to promote chemical reactions deployed in chemical and
pharmaceutical production lines may be evaluated using the
torsional analysis techniques, data monitoring devices and data
collection systems described herein.
[0886] In an illustrative and non-limiting example, the health of
rotating components such as bearings, shafts, motors, rotors,
stators, gears, and other components of mechanical/rotating
agitators to promote chemical reactions deployed in chemical and
pharmaceutical production lines may be evaluated using the
torsional analysis techniques, data monitoring devices and data
collection systems described herein.
[0887] In an illustrative and non-limiting example, the health of
rotating components such as bearings, shafts, motors, rotors,
stators, gears, and other components of propeller agitators to
promote chemical reactions deployed in chemical and pharmaceutical
production lines may be evaluated using the torsional analysis
techniques, data monitoring devices and data collection systems
described herein.
[0888] In an illustrative and non-limiting example, the health of
bearings and associated shafts, motors, rotors, stators, gears, and
other components of vehicle steering mechanisms may be evaluated
using the torsional analysis techniques, data monitoring devices
and data collection systems described herein.
[0889] In an illustrative and non-limiting example, the health of
bearings and associated shafts, motors, rotors, stators, gears, and
other components of vehicle engines may be evaluated using the
torsional analysis techniques, data monitoring devices and data
collection systems described herein.
[0890] In embodiments, a monitoring device for estimating an
anticipated lifetime of a rotating component in an industrial
machine may comprise a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for a plurality of rotating components, store historical component
performance and buffer the plurality of detection values for a
predetermined length of time; and a torsional analysis circuit
structured to utilize transitory signal analysis to analyze the
buffered detection values relative to the rotating component
specifications and anticipated state information resulting in the
identification of torsional vibration; and a system analysis
circuit structured to utilize the identified torsional vibration
and at least one of an anticipated state, historical data and a
system geometry to identify an anticipated lifetime of the rotating
component. In embodiments, the monitoring device may further
comprise a response circuit to perform at least one operation in
response to the anticipated lifetime of the rotating component,
wherein the plurality of input sensors includes at least two
sensors selected from the group consisting of a temperature sensor,
a load sensor, an optical vibration sensor, an acoustic wave
sensor, a heat flux sensor, an infrared sensor, an accelerometer, a
tri-axial vibration sensor, a tachometer, and the like. At least
one operation may comprise issuing at least one of an alert and a
warning, storing additional data in the data storage circuit,
ordering a replacement of the rotating component, scheduling
replacement of the rotating component, recommending alternatives to
the rotating component, and the like.
[0891] In embodiments, a monitoring device for evaluating the
health of a rotating component in an industrial machine may
comprise a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of a plurality of input
sensors, wherein the plurality of input sensors comprises at least
one of an angular position sensor, an angular velocity sensor and
an angular acceleration sensor positioned to measure the rotating
component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for a plurality of rotating components, store historical component
performance and buffer the plurality of detection values for a
predetermined length of time; and a torsional analysis circuit
structured to utilize transitory signal analysis to analyze the
buffered detection values relative to the rotating component
specifications and anticipated state information resulting in the
identification of torsional vibration; and a system analysis
circuit structured to utilize the identified torsional vibration
and at least one of an anticipated state, historical data and a
system geometry to identify the health of the rotating component.
In embodiments, the monitoring device may further comprise a
response circuit to perform at least one operation in response to
the health of the rotating component. The plurality of input
sensors may include at least two sensors selected from the group
consisting of a temperature sensor, a load sensor, an optical
vibration sensor, an acoustic wave sensor, a heat flux sensor, an
infrared sensor, an accelerometer, a tri-axial vibration sensor a
tachometer, and the like. The monitoring device may issue an alert
and an alarm, such as the at least one operation storing additional
data in the data storage circuit, ordering a replacement of the
rotating component, scheduling replacement of the rotating
component, recommending alternatives to the rotating component, and
the like.
[0892] In embodiments, a monitoring device for evaluating the
operational state of a rotating component in an industrial machine
may comprise a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of a plurality of input
sensors, wherein the plurality of input sensors comprises at least
one of an angular position sensor, an angular velocity sensor and
an angular acceleration sensor positioned to measure the rotating
component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for a plurality of rotating components, store historical component
performance and buffer the plurality of detection values for a
predetermined length of time; and a torsional analysis circuit
structured to utilize transitory signal analysis to analyze the
buffered detection values relative to the rotating component
specifications and anticipated state information resulting in the
identification of torsional vibration; and a system analysis
circuit structured to utilize the identified torsional vibration
and at least one of an anticipated state, historical data and a
system geometry to identify the operational state of the rotating
component. In embodiments, the operational state may be a current
or future operational state. A response circuit may perform at
least one operation in response to the operational state of the
rotating component. The at least one operation may store additional
data in the data storage circuit, order a replacement of the
rotating component, schedule a replacement of the rotating
component, recommending alternatives to the rotating component, and
the like.
[0893] In embodiments, s monitoring device for evaluating the
operational state of a rotating component in an industrial machine
may include a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of a plurality of input
sensors, wherein the plurality of input sensors comprises at least
one of an angular position sensor, an angular velocity sensor and
an angular acceleration sensor positioned to measure the rotating
component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for a plurality of rotating components, store historical component
performance and buffer the plurality of detection values for a
predetermined length of time; and a torsional analysis circuit
structured to utilize transitory signal analysis to analyze the
buffered detection values relative to the rotating component
specifications and anticipated state information resulting in the
identification of torsional vibration; and a system analysis
circuit structured to utilize the identified torsional vibration
and at least one of an anticipated state, historical data and a
system geometry to identify the operational state of the rotating
component, wherein the data acquisition circuit comprises a
multiplexer circuit whereby alternative combinations of the
detection values may be selected based on at least one of user
input, a detected state and a selected operating parameter for a
machine. The operational state may be a current or future
operational state. The at least one operation may enable or disable
one or more portions of the multiplexer circuit, or altering the
multiplexer control lines. The data acquisition circuit may include
at least two multiplexer circuits and the at least one operation
comprises changing connections between the at least two multiplexer
circuits.
[0894] In embodiments, a system for evaluating an operational state
a rotating component in a piece of equipment may comprise a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors,
wherein the plurality of input sensors comprises at least one of an
angular position sensor, an angular velocity sensor and an angular
acceleration sensor positioned to measure the rotating component; a
data storage circuit structured to store specifications, system
geometry, and anticipated state information for a plurality of
rotating components, store historical component performance and
buffer the plurality of detection values for a predetermined length
of time; and a torsional analysis circuit structured to utilize
transitory signal analysis to analyze the buffered detection values
relative to the rotating component specifications and anticipated
state information resulting in identification of any torsional
vibration; a system analysis circuit structured to utilize the
torsional vibration and at least one of an anticipated state,
historical data and a system geometry to identify the operational
state of the rotating component; and a communication module enabled
to communicate the operational state of the rotating component, the
torsional vibration and detection values to a remote server,
wherein the detection values communicated are based partly on the
operational state of the rotating component and the torsional
vibration; and a monitoring application on the remote server
structured to receive, store and jointly analyze a subset of the
detection values from the monitoring devices. The analysis of the
subset of detection values may include transitory signal analysis
to identify the presence of high frequency torsional vibration. The
monitoring application may be structured to subset detection values
based on one of: operational state, torsional vibration, type of
the rotating component, operational conditions under which
detection values were measured, and type or equipment. The analysis
of the subset of detection values may include feeding a neural net
with the subset of detection values and supplemental information to
learn to recognize various operating states, health states and
fault states utilizing deep learning techniques. The supplemental
information may include one of component specification, component
performance, equipment specification, equipment performance,
maintenance records, repair records an anticipated state model, and
the like. The operational state may include a current or future
operational state. The monitoring device may include a response
circuit to perform at least one operation in response to the
operational state of the rotating component. The at least one
operation may include storing additional data in the data storage
circuit.
[0895] In embodiments, a system for evaluating the health of a
rotating component in a piece of equipment may comprise a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors,
wherein the plurality of input sensors comprises at least one of:
an angular position sensor, an angular velocity sensor and an
angular acceleration sensor positioned to measure the rotating
component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for a plurality of rotating components, store historical component
performance and buffer the plurality of detection values for a
predetermined length of time; and a torsional analysis circuit
structured to utilize transitory signal analysis to analyze the
buffered detection values relative to the rotating component
specifications and anticipated state information resulting in
identification of torsional vibration; a system analysis circuit
structured to utilize the torsional vibration and at least one of
an anticipated state, historical data and a system geometry to
identify the health of the rotating component; and a communication
module enabled to communicate the health of the rotating component,
the torsional vibrations and detection values to a remote server,
wherein the detection values communicated are based partly on the
health of the rotating component and the torsional vibration; and a
monitoring application on the remote server structured to receive,
store and jointly analyze a subset of the detection values from the
monitoring devices. In embodiments, the analysis of the subset of
detection values may include transitory signal analysis to identify
the presence of high frequency torsional vibration. The monitoring
application may be structured to subset detection values. The
analysis of the subset of detection values may include feeding a
neural net with the subset of detection values and supplemental
information to learn to recognize various operating states, health
states and fault states utilizing deep learning techniques. The
supplemental information may include one of component
specification, component performance, equipment specification,
equipment performance, maintenance records, repair records and an
anticipated state model. The operational state may be a current or
future operational state. A response circuit may perform at least
one operation in response to the health of the rotating
component.
[0896] In embodiments, a system for estimating an anticipated
lifetime of a rotating component in a piece of equipment may
comprise a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of a plurality of input
sensors, wherein the plurality of input sensors comprises at least
one of an angular position sensor, an angular velocity sensor and
an angular acceleration sensor positioned to measure the rotating
component; a data storage circuit structured to store
specifications, system geometry, and anticipated state information
for a plurality of rotating components, store historical component
performance and buffer the plurality of detection values for a
predetermined length of time; and a torsional analysis circuit
structured to utilize transitory signal analysis to analyze the
buffered detection values relative to the rotating component
specifications and anticipated state information resulting in
identification of torsional vibration; a system analysis circuit
structured to utilize the torsional vibration and at least one of
an anticipated state, historical data and a system geometry to
identify an anticipated life the rotating component; and a
communication module enabled to communicate the anticipated life of
the rotating component, the torsional vibrations and detection
values to a remote server, wherein the detection values
communicated are based partly on the anticipated life of the
rotating component and the torsional vibration; and a monitoring
application on the remote server structured to receive, store and
jointly analyze a subset of the detection values from the
monitoring devices. In embodiments, the analysis of the subset of
detection values may include transitory signal analysis to identify
the presence of high frequency torsional vibration. The monitoring
application may be structured to subset detection values based on
one of anticipated life of the rotating component, torsional
vibration, type of the rotating component, operational conditions
under which detection values were measured, and type of equipment.
The analysis of the subset of detection values may include feeding
a neural net with the subset of detection values and supplemental
information to learn to recognize various operating states, health
states, life expectancies and fault states utilizing deep learning
techniques. The supplemental information may include one of
component specification, component performance, equipment
specification, equipment performance, maintenance records, repair
records and an anticipated state model. The monitoring device may
include a response circuit to perform at least one operation in
response to the anticipated life of the rotating component. The at
least one operation may include one of ordering a replacement of
the rotating component, scheduling replacement of the rotating
component, and recommending alternatives to the rotating
component.
[0897] In embodiments, a system for evaluating the health of a
variable frequency motor in an industrial environment may comprise
a data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of a plurality of input sensors,
wherein the plurality of input sensors comprises at least one of an
angular position sensor, an angular velocity sensor and an angular
acceleration sensor positioned to measure the rotating component; a
data storage circuit structured to store specifications, system
geometry, and anticipated state information for a plurality of
rotating components, store historical component performance and
buffer the plurality of detection values for a predetermined length
of time; and a torsional analysis circuit structured to utilize
transitory signal analysis to analyze the buffered detection values
relative to the rotating component specifications and anticipated
state information resulting in identification of torsional
vibration; a system analysis circuit structured to utilize the
torsional vibration and at least one of an anticipated state,
historical data and a system geometry to identify a motor health
parameter; and a communication module enabled to communicate the
motor health parameter, the torsional vibrations and detection
values to a remote server, wherein the detection values
communicated are based partly on the motor health parameter and the
torsional vibration; and a monitoring application on the remote
server structured to receive, store and jointly analyze a subset of
the detection values from the monitoring devices.
[0898] In embodiments, a system for data collection, processing,
and torsional analysis of a rotating component in an industrial
environment may comprise a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of a plurality of
input sensors, wherein the plurality of input sensors comprises at
least one of an angular position sensor, an angular velocity sensor
and an angular acceleration sensor positioned to measure the
rotating component; a streaming circuit for streaming at least a
subset of the acquired detection values to a remote learning
system; and a remote learning system including a torsional analysis
circuit structured to analyze the detection values relative to a
machine-based understanding of the state of the at least one
rotating component. The machine-based understanding may be
developed based on a model of the rotating component that
determines a state of the at least one rotating component based at
least in part on the relationship of the behavior of the rotating
component to an operating frequency of a component of the
industrial machine. The state of the at least one rotating
component may be at least one of an operating state, a health
state, a predicted lifetime state and a fault state. The
machine-based understanding may be developed based by providing
inputs to a deep learning machine, wherein the inputs comprise a
plurality of streams of detection values for a plurality of
rotating components and a plurality of measured state values for
the plurality of rotating components. The state of the at least one
rotating component may be at least one of an operating state, a
health state, a predicted lifetime state and a fault state.
[0899] In embodiments, information about the health or other status
or state information of or regarding a component or piece of
industrial equipment may be obtained by monitoring the condition of
various components throughout a process. Monitoring may include
monitoring the amplitude of a sensor signal measuring attributes
such as temperature, humidity, acceleration, displacement and the
like. An embodiment of a data monitoring device 9700 is shown in
FIG. 101 and may include a plurality of sensors 9706
communicatively coupled to a controller 9702. The controller 9702
may include a data acquisition circuit 9704, a signal evaluation
circuit 9708, a data storage circuit 9716 and a response circuit
9710. The signal evaluation circuit 9708 may comprise a circuit for
detecting a fault in one or more sensors, or a set of sensors, such
as an overload detection circuit 9712, a sensor fault detection
circuit 9714, or both. Additionally, the signal evaluation circuit
9708 may optionally comprise one or more of a peak detection
circuit, a phase detection circuit, a bandpass filter circuit, a
frequency transformation circuit, a frequency analysis circuit, a
phase lock loop circuit, a torsional analysis circuit, a bearing
analysis circuit, and the like.
[0900] The plurality of sensors 9706 may be wired to ports on the
data acquisition circuit 9704. The plurality of sensors 9706 may be
wirelessly connected to the data acquisition circuit 9704. The data
acquisition circuit 9704 may be able to access detection values
corresponding to the output of at least one of the plurality of
sensors 9706 where the sensors 9706 may be capturing data on
different operational aspects of a piece of equipment or an
operating component.
[0901] The selection of the plurality of sensors 9706 for a data
monitoring device 9700 designed for a specific component or piece
of equipment may depend on a variety of considerations such as
accessibility for installing new sensors, incorporation of sensors
in the initial design, anticipated operational and failure
conditions, resolution desired at various positions in a process or
plant, reliability of the sensors, and the like. The impact of a
failure, time response of a failure (e.g., warning time and/or
off-nominal modes occurring before failure), likelihood of failure,
and/or sensitivity required and/or difficulty to detection failure
conditions may drive the extent to which a component or piece of
equipment is monitored with more sensors and/or higher capability
sensors being dedicated to systems where unexpected or undetected
failure would be costly or have severe consequences.
[0902] Depending on the type of equipment, the component being
measured, the environment in which the equipment is operating and
the like, sensors 9706 may comprise, without limitation, one or
more of the following: a vibration sensor, a thermometer, a
hygrometer, a voltage sensor and/or a current sensor (for the
component and/or other sensors measuring the component), an
accelerometer, a velocity detector, a light or electromagnetic
sensor (e.g., determining temperature, composition and/or spectral
analysis, and/or object position or movement), an image sensor, a
structured light sensor, a laser-based image sensor, a thermal
imager, an acoustic wave sensor, a displacement sensor, a turbidity
meter, a viscosity meter, a axial load sensor, a radial load
sensor, a tri-axial sensor, an accelerometer, a speedometer, a
tachometer, a fluid pressure meter, an air flow meter, a horsepower
meter, a flow rate meter, a fluid particle detector, an optical
(laser) particle counter, an ultrasonic sensor, an acoustical
sensor, a heat flux sensor, a galvanic sensor, a magnetometer, a pH
sensor, and the like, including, without limitation, any of the
sensors described throughout this disclosure and the documents
incorporated by reference.
[0903] The sensors 9706 may provide a stream of data over time that
has a phase component, such as relating to acceleration or
vibration, allowing for the evaluation of phase or frequency
analysis of different operational aspects of a piece of equipment
or an operating component. The sensors 9706 may provide a stream of
data that is not conventionally phase-based, such as temperature,
humidity, load, and the like. The sensors 9706 may provide a
continuous or near continuous stream of data over time, periodic
readings, event-driven readings, and/or readings according to a
selected interval or schedule.
[0904] In embodiments, as illustrated in FIG. 101, the sensors 9706
may be part of the data monitoring device 9700, referred to herein
in some cases as a data collector, which in some cases may comprise
a mobile or portable data collector. In embodiments, as illustrated
in FIGS. 102 and 103, one or more external sensors 9724, which are
not explicitly part of a monitoring device 9718 but rather are new,
previously attached to or integrated into the equipment or
component, may be opportunistically connected to or accessed by the
monitoring device 9718. The monitoring device may include a data
acquisition circuit 9722, a signal evaluation circuit 9708, a data
storage circuit 9716 and a response circuit 9710. The signal
evaluation circuit 9708 may comprise an overload detection circuit
9712, a sensor fault detection circuit 9714, or both. Additionally,
the signal evaluation circuit 9708 may optionally comprise one or
more of a peak detection circuit, a phase detection circuit, a
bandpass filter circuit, a frequency transformation circuit, a
frequency analysis circuit, a phase lock loop circuit, a torsional
analysis circuit, a bearing analysis circuit, and the like. The
data acquisition circuit 9722 may include one or more input ports
9726.
[0905] The one or more external sensors 9724 may be directly
connected to the one or more input ports 9726 on the data
acquisition circuit 9722 of the controller 9720 or may be accessed
by the data acquisition circuit 9722 wirelessly, such as by a
reader, interrogator, or other wireless connection, such as over a
short-distance wireless protocol. In embodiments, as shown in FIG.
103, a data acquisition circuit 9722 may further comprise a
wireless communication circuit 9730. The data acquisition circuit
9722 may use the wireless communication circuit 9730 to access
detection values corresponding to the one or more external sensors
9724 wirelessly or via a separate source or some combination of
these methods.
[0906] In embodiments, the data storage circuit 9716 may be
structured to store sensor specifications, anticipated state
information and detected values. The data storage circuit 9716 may
provide specifications and anticipated state information to the
signal evaluation circuit 9708.
[0907] In embodiments, an overload detection circuit 9712 may
detect sensor overload by comparing the detected value associated
with the sensor with a detected value associated with a sensor
having a greater range/lower resolution monitoring the same
component/attribute. Inconsistencies in measured value may indicate
that the higher resolution sensor may be overloaded. In
embodiments, an overload detection circuit 9712 may detect sensor
overload by evaluating consistency of sensor reading with readings
from other sensor data (monitoring the same or different aspects of
the component/piece of equipment. In embodiments, an overload
detection circuit 9712 may detect sensor overload by evaluating
data collected by other sensors to identify conditions likely to
result in sensor overload (e.g., heat flux sensor data indicative
of the likelihood of overloading a sensor in a given location,
accelerometer data indicating a likelihood of overloading a
velocity sensor, and the like). In embodiments, an overload
detection circuit 9712 may detect sensor overload by identifying
flat line output following a rising trend. In embodiments, an
overload detection circuit 9712 may detect sensor overload by
transforming the sensor data to frequency data, using for example a
Fast Fourier Transform (FFT), and then looking for a "ski-jump" in
the frequency data which may result from the data being clipped due
to an overloaded sensor. A sensor fault detection circuit 9714 may
identify failure of the sensor itself, sensor health, or potential
concerns regarding validity of sensor data. Rate of value change
may be used to identify failure of the sensor itself. For example,
a sudden jump to a maximum output may indicate a failure in the
sensor rather than an overload of the sensor. In embodiments, an
overload detection circuit 9712 and/or a sensor fault detection
circuit 9712 may utilize sensor specifications, anticipated state
information, sensor models and the like in the identification of
sensor overload, failure, error, invalid data, and the like. In
embodiments, the overload detection circuit 9712 or the sensor
fault detection circuit 9714 may use detection values from other
sensors and output from additional components such as a peak
detection circuit and/or a phase detection circuit and/or a
bandpass filter circuit and/or a frequency transformation circuit
and/or a frequency analysis circuit and/or a phase lock loop
circuit and the like to identify potential sources for the
identified sensor overload, sensor faults, sensor failure, or the
like. Sources or factors involved in sensor overload may include
limitations on sensor range, sensor resolution, and sensor sampling
frequency. Sources of apparent sensor overload may be due to a
range, resolution or sampling frequency of a multiplexor supplying
detection values associated with the sensor. Sources of factors
involved in apparent sensor faults or failures may include
environmental conditions; for example, excessive heat or cold may
be associated with damage to semiconductor-based sensors, which may
result in erratic sensor data, failure of a sensor to produce data,
data that appears out of the range of normal behavior (e.g., large,
discrete jumps in temperature for a system that does not normally
experience such changes). Surges in current and/or voltage may be
associated with damage to electrically connected sensors with
sensitive components. Excessive vibration may result in physical
damage to sensitive components of a sensor such as wires and/or
connectors. An impact, which may be indicated by sudden
acceleration or acoustical data may result in physical damage to a
sensor with sensitive components such as wires and/or connectors. A
rapid increase in humidity in the environment surrounding a sensor
or an absence of oxygen may indicate water damage to a sensor. A
sudden absence of signal from a sensor may be indicative of sensor
disconnection which may due to vibration, impact and the like. A
sensor that requires power may run out of battery power or be
disconnected from a power source. In embodiments, the overload
detection circuit 9712 or the sensor fault detection circuit 9714
may output a sensor status where the sensor status may be one of
sensor overload, sensor failure, sensor fault, sensor healthy, and
the like. The sensor fault detection circuit 9714 may determine one
of a sensor fault status and a sensor validity status.
[0908] In embodiments, as illustrated in FIG. 104, the data
acquisition circuit 9722 may further comprise a multiplexer circuit
9731 as described elsewhere herein. Outputs from the multiplexer
circuit 9731 may be utilized by the signal evaluation circuit 9708.
The response circuit 9710 may have the ability to turn on or off
portions of the multiplexor circuit 9731. The response circuit 9710
may have the ability to control the control channels of the
multiplexor circuit 9731.
[0909] In embodiments, the response circuit 9710 may initiate a
variety of actions based on the sensor status provided by the
overload detection circuit 9712. The response circuit 9710 may
continue using the sensor if the sensor status is "sensor healthy."
The response circuit 9710 may adjust a sensor scaling value (e.g.,
from 100 mV/gram to 10 mV/gram). The response circuit 9710 may
increase an acquisition range for an alternate sensor. The response
circuit 9710 may back sensor data out of previous calculations and
evaluations such as bearing analysis, torsional analysis and the
like. The response circuit 9710 may use projected or anticipated
data (based on data acquired prior to overload/failure) in place of
the actual sensor data for calculations and evaluations such as
bearing analysis, torsional analysis and the like. The response
circuit 9710 may issue an alarm. The response circuit 9710 may
issue an alert that may comprise notification that the sensor is
out of range together with information regarding the extent of the
overload such as "overload range--data response may not be reliable
and/or linear", "destructive range--sensor may be damaged," and the
like. The response circuit 9710 may issue an alert where the alert
may comprise information regarding the effect of sensor load such
as "unable to monitor machine health" due to sensor
overload/failure," and the like.
[0910] In embodiments, the response circuit 9710 may cause the data
acquisition circuit 9704 to enable or disable the processing of
detection values corresponding to certain sensors based on the
sensor statues described above. This may include switching to
sensors having different response rates, sensitivity, ranges, and
the like; accessing new sensors or types of sensors, accessing data
from multiple sensors, recruiting additional data collectors (such
as routing the collectors to a point of work, using routing methods
and systems disclosed throughout this disclosure and the documents
incorporated by reference) and the like. Switching may be
undertaken based on a model, a set of rules, or the like. In
embodiments, switching may be under control of a machine learning
system, such that switching is controlled based on one or more
metrics of success, combined with input data, over a set of trials,
which may occur under supervision of a human supervisor or under
control of an automated system. Switching may involve switching
from one input port to another (such as to switch from one sensor
to another). Switching may involve altering the multiplexing of
data, such as combining different streams under different
circumstances. Switching may involve activating a system to obtain
additional data, such as moving a mobile system (such as a robotic
or drone system), to a location where different or additional data
is available (such as positioning an image sensor for a different
view or positioning a sonar sensor for a different direction of
collection) or to a location where different sensors can be
accessed (such as moving a collector to connect up to a sensor that
is disposed at a location in an environment by a wired or wireless
connection). This switching may be implemented by changing the
control signals for a multiplexor circuit 9731 and/or by turning on
or off certain input sections of the multiplexor circuit 9731.
[0911] In embodiments, the response circuit 9710 may make
recommendations for the replacement of certain sensors in the
future with sensors having different response rates, sensitivity,
ranges, and the like. The response circuit 9710 may recommend
design alterations for future embodiments of the component, the
piece of equipment, the operating conditions, the process, and the
like.
[0912] In embodiments, the response circuit 9710 may recommend
maintenance at an upcoming process stop or initiate a maintenance
call where the maintenance may include the replacement of the
sensor with the same or an alternate type of sensor having a
different response rate, sensitivity, range and the like. In
embodiments, the response circuit 9710 may implement or recommend
process changes--for example to lower the utilization of a
component that is near a maintenance interval, operating
off-nominally, or failed for purpose but still at least partially
operational, to change the operating speed of a component (such as
to put it in a lower-demand mode), to initiate amelioration of an
issue (such as to signal for additional lubrication of a roller
bearing set, or to signal for an alignment process for a system
that is out of balance), and the like.
[0913] In embodiments, the signal evaluation circuit 9708 and/or
the response circuit 9710 may periodically store certain detection
values in the data storage circuit 9716 to enable the tracking of
component performance over time. In embodiments, based on sensor
status, as described elsewhere herein recently measured sensor data
and related operating conditions such as RPMs, component loads,
temperatures, pressures, vibrations or other sensor data of the
types described throughout this disclosure in the data storage
circuit 9716 to enable the backing out of overloaded/failed sensor
data. The signal evaluation circuit 9708 may store data at a higher
data rate for greater granularity in future processing, the ability
to reprocess at different sampling rates, and/or to enable
diagnosing or post-processing of system information where
operational data of interest is flagged, and the like.
[0914] In embodiments as shown in FIGS. 105, 106, 107, and 108, a
data monitoring system 9726 may include at least one data
monitoring device 9728. At least one data monitoring device 9728
may include sensors 9706 and a controller 9730 comprising a data
acquisition circuit 9704, a signal evaluation circuit 9708, a data
storage circuit 9716, and a communication circuit 9754 to allow
data and analysis to be transmitted to a monitoring application
9736 on a remote server 9734. The signal evaluation circuit 9708
may include at least an overload detection circuit 9712. The signal
evaluation circuit 9708 may periodically share data with the
communication circuit 9732 for transmittal to the remote server
9734 to enable the tracking of component and equipment performance
over time and under varying conditions by a monitoring application
9736. Based on the sensor status, the signal evaluation circuit
9708 and/or response circuit 9710 may share data with the
communication circuit 9732 for transmittal to the remote server
9734 based on the fit of data relative to one or more criteria.
Data may include recent sensor data and additional data such as
RPMs, component loads, temperatures, pressures, vibrations, and the
like for transmittal. The signal evaluation circuit 9708 may share
data at a higher data rate for transmittal to enable greater
granularity in processing on the remote server.
[0915] In embodiments, as shown in FIG. 105, the communication
circuit 9732 may communicate data directly to a remote server 9734.
In embodiments as shown in FIG. 106, the communication circuit 9732
may communicate data to an intermediate computer 9738 which may
include a processor 9740 running an operating system 9742 and a
data storage circuit 9744.
[0916] In embodiments, as illustrated in FIGS. 107 and 108, a data
collection system 9746 may have a plurality of monitoring devices
9728 collecting data on multiple components in a single piece of
equipment, collecting data on the same component across a plurality
of pieces of equipment, (both the same and different types of
equipment) in the same facility as well as collecting data from
monitoring devices in multiple facilities. A monitoring application
9736 on a remote server 9734 may receive and store one or more of
detection values, timing signals and data coming from a plurality
of the various monitoring devices 9728.
[0917] In embodiments, as shown in FIG. 107, the communication
circuit 9732 may communicated data directly to a remote server
9734. In embodiments, as shown in FIG. 108, the communication
circuit 9732 may communicate data to an intermediate computer 9738
which may include a processor 9740 running an operating system 9742
and a data storage circuit 9744. There may be an individual
intermediate computer 9738 associated with each monitoring device
9728 or an individual intermediate computer 9738 may be associated
with a plurality of monitoring devices 9728 where the intermediate
computer 9738 may collect data from a plurality of data monitoring
devices and send the cumulative data to the remote server 9734.
Communication to the remote server 9734 may be streaming, batch
(e.g., when a connection is available) or opportunistic.
[0918] The monitoring application 9736 may select subsets of the
detection values to be jointly analyzed. Subsets for analysis may
be selected based on a single type of sensor, component or a single
type of equipment in which a component is operating. Subsets for
analysis may be selected or grouped based on common operating
conditions such as size of load, operational condition (e.g.,
intermittent, continuous), operating speed or tachometer, common
ambient environmental conditions such as humidity, temperature, air
or fluid particulate, and the like. Subsets for analysis may be
selected based on the effects of other nearby equipment such as
nearby machines rotating at similar frequencies, nearby equipment
producing electromagnetic fields, nearby equipment producing heat,
nearby equipment inducing movement or vibration, nearby equipment
emitting vapors, chemicals or particulates, or other potentially
interfering or intervening effects.
[0919] In embodiments, the monitoring application 9736 may analyze
the selected subset. In an illustrative example, data from a single
sensor may be analyzed over different time periods such as one
operating cycle, several operating cycles, a month, a year, the
life of the component or the like. Data from multiple sensors of a
common type measuring a common component type may also be analyzed
over different time periods. Trends in the data such as changing
rates of change associated with start-up or different points in the
process may be identified. Correlation of trends and values for
different sensors may be analyzed to identify those parameters
whose short-term analysis might provide the best prediction
regarding expected sensor performance. This information may be
transmitted back to the monitoring device to update sensor models,
sensor selection, sensor range, sensor scaling, sensor sampling
frequency, types of data collected and analyzed locally or to
influence the design of future monitoring devices.
[0920] In embodiments, the monitoring application 9736 may have
access to equipment specifications, equipment geometry, component
specifications, component materials, anticipated state information
for a plurality of sensors, operational history, historical
detection values, sensor life models and the like for use analyzing
the selected subset using rule-based or model-based analysis. The
monitoring application 9736 may provide recommendations regarding
sensor selection, additional data to collect, or data to store with
sensor data. The monitoring application 9736 may provide
recommendations regarding scheduling repairs and/or maintenance.
The monitoring application 9736 may provide recommendations
regarding replacing a sensor. The replacement sensor may match the
sensor being replaced or the replacement sensor may have a
different range, sensitivity, sampling frequency and the like.
[0921] In embodiments, the monitoring application 9736 may include
a remote learning circuit structured to analyze sensor status data
(e.g., sensor overload, sensor faults, sensor failure) together
with data from other sensors, failure data on components being
monitored, equipment being monitored, product being produced, and
the like. The remote learning system may identify correlations
between sensor overload and data from other sensors.
[0922] Clause 1: In embodiments, a monitoring system for data
collection in an industrial environment, the monitoring system
comprising: a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of a plurality of input
sensors; a data storage circuit structured to store sensor
specifications, anticipated state information and detected values;
a signal evaluation circuit comprising: an overload identification
circuit structured to determine a sensor overload status of at
least one sensor in response to the plurality of detection values
and at least one of anticipated state information and sensor
specification; a sensor fault detection circuit structured to
determine one of a sensor fault status and a sensor validity status
of at least one sensor in response to the plurality of detection
values and at least one of anticipated state information and sensor
specification; and a response circuit structured to perform at
least one operation in response to one of a sensor overload status,
a sensor health status, and a sensor validity status. A monitoring
system of clause 1, the system further comprising a mobile data
collector for collecting data from the plurality of input sensors.
3. The monitoring system of clause 1, wherein the at least one
operation comprises issuing an alert or an alarm. 4. The monitoring
system of clause 1, wherein the at least one operation further
comprises storing additional data in the data storage circuit. 5.
The monitoring system of clause 1, the system further comprising a
multiplexor (MUX) circuit.6. The monitoring system of clause 5,
wherein the at least one operation comprises at least one of
enabling or disabling one or more portions of the multiplexer
circuit and altering the multiplexer control lines. 7. The
monitoring system of clause 5, the system further comprising at
least two multiplexer (MUX) circuits and the at least one operation
comprises changing connections between the at least two multiplexer
circuits. 8. The monitoring system of clause 7, the system further
comprising a MUX control circuit structured to interpret a subset
of the plurality of detection values and provide the logical
control of the MUX and the correspondence of MUX input and detected
values as a result, wherein the logic control of the MUX comprises
adaptive scheduling of the multiplexer control lines. 9. A system
for data collection, processing, and component analysis in an
industrial environment comprising: a plurality of monitoring
devices, each monitoring device comprising: a data acquisition
circuit structured to interpret a plurality of detection values,
each of the plurality of detection values corresponding to at least
one of a plurality of input sensors; a data storage for storing
specifications and anticipated state information for a plurality of
sensor types and buffering the plurality of detection values for a
predetermined length of time; a signal evaluation circuit
comprising: an overload identification circuit structured to
determine a sensor overload status of at least one sensor in
response to the plurality of detection values and at least one of
anticipated state information and sensor specification; a sensor
fault detection circuit structured to determine one of a sensor
fault status and a sensor validity status of at least one sensor in
response to the plurality of detection values and at least one of
anticipated state information and sensor specification; and a
response circuit structured to perform at least one operation in
response to one of a sensor overload status, a sensor health
status, and a sensor validity status; a communication circuit
structured to communicate with a remote server providing one of the
sensor overload status, the sensor health status, and the sensor
validity status and a portion of the buffered detection values to
the remote server; and a monitoring application on the remote
server structured to: receive the at least one selected detection
value and one of the sensor overload status, the sensor health
status, and the sensor validity status; jointly analyze a subset of
the detection values received from the plurality of monitoring
devices; and recommend an action. 10. The system of clause 9, with
at least one of the monitoring devices further comprising a mobile
data collector for collecting data from the plurality of input
sensors. 11. The system of clause 9, wherein the at least one
operation comprises issuing an alert or an alarm. 12. The
monitoring system of clause 9, wherein the at least one operation
further comprises storing additional data in the data storage
circuit. 13. The system of clause 9, with at least one of the
monitoring devices further comprising further comprising a
multiplexor (MUX) circuit. 14. The system of clause 13, wherein the
at least one operation comprises at least one of enabling or
disabling one or more portions of the multiplexer circuit and
altering the multiplexer control lines. 15. The system of clause 9,
at least one of the monitoring devices further comprising at least
two multiplexer (MUX) circuits and the at least one operation
comprises changing connections between the at least two multiplexer
circuits. 16. The monitoring system of clause 15, the system
further comprising a MUX control circuit structured to interpret a
subset of the plurality of detection values and provide the logical
control of the MUX and the correspondence of MUX input and detected
values as a result, wherein the logic control of the MUX comprises
adaptive scheduling of the multiplexer control lines. 17. The
system of clause 9, wherein the monitoring application comprises a
remote learning circuit structured to analyze sensor status data
together sensor data and identify correlations between sensor
overload and data from other systems. 18. The system of clause 9,
the monitoring application structured to subset detection values
based on one of the sensor overload status, the sensor health
status, the sensor validity status, the anticipated life of a
sensor associated with detection values, the anticipated type of
the equipment associated with detection values, and operational
conditions under which detection values were measured. 19. The
system of clause 9, wherein the supplemental information comprises
one of sensor specification, sensor historic performance,
maintenance records, repair records and an anticipated state model.
20. The system of clause 19, wherein the analysis of the subset of
detection values comprises feeding a neural net with the subset of
detection values and supplemental information to learn to recognize
various sensor operating states, health states, life expectancies
and fault states utilizing deep learning techniques.
[0923] Referring to FIGS. 109 through 136, embodiments of the
present disclosure, including those involving expert systems,
self-organization, machine learning, artificial intelligence, and
the like, may benefit from the use of a neural net, such as a
neural net trained for pattern recognition, for classification of
one or more parameters, characteristics, or phenomena, for support
of autonomous control, and other purposes. References to a neural
net throughout this disclosure should be understood to encompass a
wide range of different types of neural networks, machine learning
systems, artificial intelligence systems, and the like, such as
feed forward neural networks, radial basis function neural
networks, self-organizing neural networks (e.g., Kohonen
self-organizing neural networks), recurrent neural networks,
modular neural networks, artificial neural networks, physical
neural networks, multi-layered neural networks, convolutional
neural networks, hybrids of neural networks with other expert
systems (e.g., hybrid fuzzy logic--neural network systems),
autoencoder neural networks, probabilistic neural networks, time
delay neural networks, convolutional neural networks, regulatory
feedback neural networks, radial basis function neural networks,
recurrent neural networks, Hopfield neural networks, Boltzmann
machine neural networks, self-organizing map (SOM) neural networks,
learning vector quantization (LVQ) neural networks, fully recurrent
neural networks, simple recurrent neural networks, echo state
neural networks, long short-term memory neural networks,
bi-directional neural networks, hierarchical neural networks,
stochastic neural networks, genetic scale RNN neural networks,
committee of machines neural networks, associative neural networks,
physical neural networks, instantaneously trained neural networks,
spiking neural networks, neocognition neural networks, dynamic
neural networks, cascading neural networks, neuro-fuzzy neural
networks, compositional pattern-producing neural networks, memory
neural networks, hierarchical temporal memory neural networks, deep
feed forward neural networks, gated recurrent unit (GCU) neural
networks, auto encoder neural networks, variational auto encoder
neural networks, de-noising auto encoder neural networks, sparse
auto-encoder neural networks, Markov chain neural networks,
restricted Boltzmann machine neural networks, deep belief neural
networks, deep convolutional neural networks, deconvolutional
neural networks, deep convolutional inverse graphics neural
networks, generative adversarial neural networks, liquid state
machine neural networks, extreme learning machine neural networks,
echo state neural networks, deep residual neural networks, support
vector machine neural networks, neural Turing machine neural
networks, and/or holographic associative memory neural networks, or
hybrids or combinations of the foregoing, or combinations with
other expert systems, such as rule-based systems, model-based
systems (including ones based on physical models, statistical
models, flow-based models, biological models, biomimetic models,
and the like).
[0924] In embodiments, the foregoing neural network may be
configured to connect with a DAQ instrument and other data
collectors that may receive analog signals from one or more
sensors. The foregoing neural networks may also be configured to
interface with, connect to, or integrate with expert systems that
can be local and/or available through one or more cloud networks.
In embodiments, FIGS. 110 through 136 depict exemplary neural
networks and FIG. 109 depicts a legend showing the various
components of the neural networks depicted throughout FIGS. 110 to
136. FIG. 109 depicts the various neural net components 10000, as
depicted in cells 10002 for which there are assigned functions and
requirements. In embodiments, the various neural net examples may
include back fed data/sensor cells 10010, data/sensor cells 10012,
noisy input cells, 10014, and hidden cells, 10018. The neural net
components 10000 also include the other following cells 10002:
probabilistic hidden cells 10020, spiking hidden cells 10022,
output cells 10024, match input/output cell 10028, recurrent cell
10030, memory cell, 10032, different memory cell 10034, kernals
10038 and convolution or pool cells 10040.
[0925] In FIG. 110, a streaming data collection system 10050 may
include a DAQ instrument 10052 or other data collectors that may
gather analog signals from sensors including sensor 10060, sensor
10062 and sensor 10064. The streaming data collection system 10050
may include a perceptron neural network 10070 that may connect to,
integrate with, or interface with an expert system 10080. In FIG.
111, a streaming data collection system 10090 may include the DAQ
instrument 10052 or other data collectors that may gather analog
signals from sensors including the sensors 10060, 10062, 10064. The
streaming data collection system 10090 may include a feed forward
neural network 10092 that may connect to, integrate with, or
interface with the expert system 10080. In FIG. 112, a streaming
data collection system 10100 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10100 may include a radial basis neural
network 10102 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 113, a streaming data
collection system 10110 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10110 may include a deep feed forward neural
network 10112 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 114, a streaming data
collection system 10120 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10120 may include a recurrent neural network
10122 that may connect to, integrate with, or interface with the
expert system 10080.
[0926] In FIG. 115, a streaming data collection system 10130 may
include the DAQ instrument 10052 or other data collectors that may
gather analog signals from sensors including the sensors 10060,
10062, 10064. The streaming data collection system 10130 may
include a long/short term neural network 10132 that may connect to,
integrate with, or interface with the expert system 10080. In FIG.
116, a streaming data collection system 10140 may include the DAQ
instrument 10052 or other data collectors that may gather analog
signals from sensors including the sensors 10060, 10062, 10064. The
streaming data collection system 10140 may include a gated
recurrent neural network 10142 that may connect to, integrate with,
or interface with the expert system 10080. In FIG. 117, a streaming
data collection system 10150 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10150 may include an auto encoder neural
network 10152 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 118, a streaming data
collection system 10160 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10160 may include a variational neural network
10162 that may connect to, integrate with, or interface with the
expert system 10080. In FIG. 119, a streaming data collection
system 10170 may include the DAQ instrument 10052 or other data
collectors that may gather analog signals from sensors including
the sensors 10060, 10062, 10064. The streaming data collection
system 10170 may include a denoising neural network 10172 that may
connect to, integrate with, or interface with the expert system
10080. In FIG. 120, a streaming data collection system 10180 may
include the DAQ instrument 10052 or other data collectors that may
gather analog signals from sensors including the sensors 10060,
10062, 10064. The streaming data collection system 10180 may
include a sparse neural network 10182 that may connect to,
integrate with, or interface with the expert system 10080. In FIG.
121, a streaming data collection system 10190 may include the DAQ
instrument 10052 or other data collectors that may gather analog
signals from sensors including the sensors 10060, 10062, 10064. The
streaming data collection system 10190 may include a Markov chain
neural network 10182 that may connect to, integrate with, or
interface with the expert system 10080.
[0927] In FIG. 122, a streaming data collection system 10200 may
include the DAQ instrument 10052 or other data collectors that may
gather analog signals from sensors including the sensors 10060,
10062, 10064. The streaming data collection system 10200 may
include a Hopfield network neural network 10202 that may connect
to, integrate with, or interface with the expert system 10080. In
FIG. 123, a streaming data collection system 10210 may include the
DAQ instrument 10052 or other data collectors that may gather
analog signals from sensors including the sensors 10060, 10062,
10064. The streaming data collection system 10210 may include a
Boltzmann machine neural network 10212 that may connect to,
integrate with, or interface with the expert system 10080. In FIG.
124, a streaming data collection system 10220 may include the DAQ
instrument 10052 or other data collectors that may gather analog
signals from sensors including the sensors 10060, 10062, 10064. The
streaming data collection system 10220 may include a restricted BM
neural network 10222 that may connect to, integrate with, or
interface with the expert system 10080. In FIG. 125, a streaming
data collection system 10230 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10230 may include a deep belief neural
network 10232 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 126, a streaming data
collection system 10240 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10240 may include a deep convolutional neural
network 10242 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 127, a streaming data
collection system 10250 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10250 may include a deconvolutional neural
network 10242 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 128, a streaming data
collection system 10260 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10260 may include a deep convolutional inverse
graphics neural network 10262 that may connect to, integrate with,
or interface with the expert system 10080. In FIG. 129, a streaming
data collection system 10270 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10270 may include a generative adversarial
neural network 10272 that may connect to, integrate with, or
interface with the expert system 10080. In FIG. 130, a streaming
data collection system 10280 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10280 may include a liquid state machine
neural network 10282 that may connect to, integrate with, or
interface with the expert system 10080. In FIG. 131, a streaming
data collection system 10290 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10290 may include an extreme learning
machine neural network 10292 that may connect to, integrate with,
or interface with the expert system 10080. In FIG. 132, a streaming
data collection system 10300 may include the DAQ instrument 10052
or other data collectors that may gather analog signals from
sensors including the sensors 10060, 10062, 10064. The streaming
data collection system 10300 may include an echo state neural
network 10302 that may connect to, integrate with, or interface
with the expert system 10080. In FIG. 133, a streaming data
collection system 10310 may include the DAQ instrument 10052 or
other data collectors that may gather analog signals from sensors
including the sensors 10060, 10062, 10064. The streaming data
collection system 10310 may include a deep residual neural network
10312 that may connect to, integrate with, or interface with the
expert system 10080. In FIG. 134, a streaming data collection
system 10320 may include the DAQ instrument 10052 or other data
collectors that may gather analog signals from sensors including
the sensors 10060, 10062, 10064. The streaming data collection
system 10320 may include a Kohonen neural network 10322 that may
connect to, integrate with, or interface with the expert system
10080. In FIG. 135, a streaming data collection system 10330 may
include the DAQ instrument 10052 or other data collectors that may
gather analog signals from sensors including the sensors 10060,
10062, 10064. The streaming data collection system 10330 may
include a support vector machine neural network 10332 that may
connect to, integrate with, or interface with the expert system
10080. In FIG. 136, a streaming data collection system 10340 may
include the DAQ instrument 10052 or other data collectors that may
gather analog signals from sensors including the sensors 10060,
10062, 10064. The streaming data collection system 10340 may
include a neural Turing machine neural network 10342 that may
connect to, integrate with, or interface with the expert system
10080.
[0928] The foregoing neural networks may have a variety of nodes or
neurons, which may perform a variety of functions on inputs, such
as inputs received from sensors or other data sources, including
other nodes. Functions may involve weights, features, feature
vectors, and the like. Neurons may include perceptron, neurons that
mimic biological functions (such as of the human senses of touch,
vision, taste, hearing, and smell), and the like. Continuous
neurons, such as with sigmoidal activation, may be used in the
context of various forms of neural net, such as where back
propagation is involved.
[0929] In many embodiments, an expert system or neural network may
be trained, such as by a human operator or supervisor, or based on
a data set, model, or the like. Training may include presenting the
neural network with one or more training data sets that represent
values, such as sensor data, event data, parameter data, and other
types of data (including the many types described throughout this
disclosure), as well as one or more indicators of an outcome, such
as an outcome of a process, an outcome of a calculation, an outcome
of an event, an outcome of an activity, or the like. Training may
include training in optimization, such as training a neural network
to optimize one or more systems based on one or more optimization
approaches, such as Bayesian approaches, parametric Bayes
classifier approaches, k-nearest-neighbor classifier approaches,
iterative approaches, interpolation approaches, Pareto optimization
approaches, algorithmic approaches, and the like. Feedback may be
provided in a process of variation and selection, such as with a
genetic algorithm that evolves one or more solutions based on
feedback through a series of rounds.
[0930] In embodiments, a plurality of neural networks may be
deployed in a cloud platform that receives data streams and other
inputs collected (such as by mobile data collectors) in one or more
industrial environments and transmitted to the cloud platform over
one or more networks, including using network coding to provide
efficient transmission. In the cloud platform, optionally using
massively parallel computational capability, a plurality of
different neural networks of several types (including modular
forms, structure-adaptive forms, hybrids, and the like) may be used
to undertake prediction, classification, control functions, and
provide other outputs as described in connection with expert
systems disclosed throughout this disclosure. The different neural
networks may be structured to compete with each other (optionally
including the use of evolutionary algorithms, genetic algorithms,
or the like), such that an appropriate type of neural network, with
appropriate input sets, weights, node types and functions, and the
like, may be selected, such as by an expert system, for a specific
task involved in a given context, workflow, environment process,
system, or the like.
[0931] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
feed forward neural network, which moves information in one
direction, such as from a data input, like an analog sensor located
on or proximal to an industrial machine, through a series of
neurons or nodes, to an output. Data may move from the input nodes
to the output nodes, optionally passing through one or more hidden
nodes, without loops. In embodiments, feedforward neural networks
may be constructed with various types of units, such as binary
McCulloch-Pitts neurons, the simplest of which is a perceptron.
[0932] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
radial basis function (RBF) neural network, which may be preferred
in some situations involving interpolation in a multi-dimensional
space (such as where interpolation is helpful in optimizing a
multi-dimensional function, such as for optimizing a data
marketplace as described here, optimizing the efficiency or output
of a power generation system, a factory system, or the like, or
other situation involving multiple dimensions). In embodiments,
each neuron in the RBF neural network stores an example from a
training set as a "prototype." Linearity involved in the
functioning of this neural network offers RBF the advantage of not
typically suffering from problems with local minima or maxima.
[0933] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
radial basis function (RBF) neural network, such as one that
employs a distance criterion with respect to a center (e.g., a
Gaussian function). A radial basis function may be applied as a
replacement for a hidden layer (such as a sigmoidal hidden layer
transfer) in a multi-layer perceptron. An RBF network may have two
layers, such as the case where an input is mapped onto each RBF in
a hidden layer. In embodiments, an output layer may comprise a
linear combination of hidden layer values representing, for
example, a mean predicted output. The output layer value may
provide an output that is the same as or similar to that of a
regression model in statistics. In classification problems, the
output layer may be a sigmoid function of a linear combination of
hidden layer values, representing a posterior probability.
Performance in both cases is often improved by shrinkage
techniques, such as ridge regression in classical statistics. This
corresponds to a prior belief in small parameter values (and
therefore smooth output functions) in a Bayesian framework. RBF
networks may avoid local minima, because the only parameters that
are adjusted in the learning process are the linear mapping from
hidden layer to output layer. Linearity ensures that the error
surface is quadratic and therefore has a single minimum. In
regression problems, this can be found in one matrix operation. In
classification problems, the fixed non-linearity introduced by the
sigmoid output function may be handled using an iteratively
re-weighted least squares function or the like.
[0934] RBF networks may use kernel methods such as support vector
machines (SVM) and Gaussian processes (where the RBF is the kernel
function). A non-linear kernel function may be used to project the
input data into a space where the learning problem can be solved
using a linear model.
[0935] In embodiments, an RBF neural network may include an input
layer, a hidden layer, and a summation layer. In the input layer,
one neuron appears in the input layer for each predictor variable.
In the case of categorical variables, N-1 neurons are used, where N
is the number of categories. The input neurons may, in embodiments,
standardize the value ranges by subtracting the median and dividing
by the interquartile range. The input neurons may then feed the
values to each of the neurons in the hidden layer. In the hidden
layer, a variable number of neurons may be used (determined by the
training process). Each neuron may consist of a radial basis
function that is centered on a point with as many dimensions as a
number of predictor variables. The spread (e.g., radius) of the RBF
function may be different for each dimension. The centers and
spreads may be determined by training. When presented with a vector
of input values from the input layer, a hidden neuron may compute a
Euclidean distance of the test case from the neuron's center point
and then apply the RBF kernel function to this distance, such as
using the spread values. The resulting value may then be passed to
the summation layer. In the summation layer, the value coming out
of a neuron in the hidden layer may be multiplied by a weight
associated with the neuron and may add to the weighted values of
other neurons. This sum becomes the output. For classification
problems, one output is produced (with a separate set of weights
and summation units) for each target category. The value output for
a category is the probability that the case being evaluated has
that category. In training of an RBF, various parameters may be
determined, such as the number of neurons in a hidden layer, the
coordinates of the center of each hidden-layer function, the spread
of each function in each dimension, and the weights applied to
outputs as they pass to the summation layer. Training may be used
by clustering algorithms (such as k-means clustering), by
evolutionary approaches, and the like.
[0936] In embodiments, a recurrent neural network may have a
time-varying, real-valued (more than just zero or one) activation
(output). Each connection may have a modifiable real-valued weight.
Some of the nodes are called labeled nodes, some output nodes, and
others hidden nodes. For supervised learning in discrete time
settings, training sequences of real-valued input vectors may
become sequences of activations of the input nodes, one input
vector at a time. At each time step, each non-input unit may
compute its current activation as a nonlinear function of the
weighted sum of the activations of all units from which it receives
connections. The system can explicitly activate (independent of
incoming signals) some output units at certain time steps.
[0937] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
self-organizing neural network, such as a Kohonen self-organizing
neural network, such as for visualization of views of data, such as
low-dimensional views of high-dimensional data. The self-organizing
neural network may apply competitive learning to a set of input
data, such as from one or more sensors or other data inputs from or
associated with an industrial machine. In embodiments, the
self-organizing neural network may be used to identify structures
in data, such as unlabeled data, such as in data sensed from a
range of vibration, acoustic, or other analog sensors in an
industrial environment, where sources of the data are unknown (such
as where vibrations may be coming from any of a range of unknown
sources). The self-organizing neural network may organize
structures or patterns in the data, such that they can be
recognized, analyzed, and labeled, such as identifying structures
as corresponding to vibrations induced by the movement of a floor,
or acoustic signals created by high frequency rotation of a shaft
of a somewhat distant machine.
[0938] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
recurrent neural network, which may allow for a bi-directional flow
of data, such as where connected units (e.g., neurons or nodes)
form a directed cycle. Such a network may be used to model or
exhibit dynamic temporal behavior, such as those involved in
dynamic systems including a wide variety of the industrial machines
and devices described throughout this disclosure, such as a power
generation machine operating at variable speeds or frequencies in
variable conditions with variable inputs, a robotic manufacturing
system, a refining system, or the like, where dynamic system
behavior involves complex interactions that an operator may desire
to understand, predict, control and/or optimize. For example, the
recurrent neural network may be used to anticipate the state (such
as a maintenance state, a fault state, an operational state, or the
like), of an industrial machine, such as one performing a dynamic
process or action. In embodiments, the recurrent neural network may
use internal memory to process a sequence of inputs, such as from
other nodes and/or from sensors and other data inputs from the
industrial environment, of the various types described herein. In
embodiments, the recurrent neural network may also be used for
pattern recognition, such as for recognizing an industrial machine
based on a sound signature, a heat signature, a set of feature
vectors in an image, a chemical signature, or the like. In a
non-limiting example, a recurrent neural network may recognize a
shift in an operational mode of a turbine, a generator, a motor, a
compressor, or the like (such as a gear shift) by learning to
classify the shift from a training data set consisting of a stream
of data from tri-axial vibration sensors and/or acoustic sensors
applied to one or more of such machines.
[0939] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
modular neural network, which may comprise a series of independent
neural networks (such as ones of various types described herein)
that are moderated by an intermediary. Each of the independent
neural networks in the modular neural network may work with
separate inputs, accomplishing subtasks that make up the task the
modular network as whole is intended to perform. For example, a
modular neural network may comprise a recurrent neural network for
pattern recognition, such as to recognize what type of industrial
machine is being sensed by one or more sensors that are provided as
input channels to the modular network and an RBF neural network for
optimizing the behavior of the machine once understood. The
intermediary may accept inputs of each of the individual neural
networks, process them, and create output for the modular neural
network, such an appropriate control parameter, a prediction of
state, or the like.
[0940] Combinations among any of the pairs, triplets, or larger
combinations, of the various neural network types described herein,
are encompassed by the present disclosure. This may include
combinations where an expert system uses one neural network for
recognizing a pattern (e.g., a pattern indicating a problem or
fault condition) and a different neural network for self-organizing
an activity or work flow based on the recognized pattern (such as
providing an output governing autonomous control of a system in
response to the recognized condition or pattern). This may also
include combinations where an expert system uses one neural network
for classifying an item (e.g., identifying a machine, a component,
or an operational mode) and a different neural network for
predicting a state of the item (e.g., a fault state, an operational
state, an anticipated state, a maintenance state, or the like).
Modular neural networks may also include situations where an expert
system uses one neural network for determining a state or context
(such as a state of a machine, a process, a work flow, a
marketplace, a storage system, a network, a data collector, or the
like) and a different neural network for self-organizing a process
involving the state or context (e.g., a data storage process, a
network coding process, a network selection process, a data
marketplace process, a power generation process, a manufacturing
process, a refining process, a digging process, a boring process,
or other process described herein).
[0941] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
physical neural network where one or more hardware elements is used
to perform or simulate neural behavior. In embodiments, one or more
hardware neurons may be configured to stream voltage values that
represent analog vibration sensor data voltage values, to calculate
velocity information from analog sensor inputs representing
acoustic, vibration or other data, to calculation acceleration
information from sensor inputs representing acoustic, vibration, or
other data, or the like. One or more hardware nodes may be
configured to stream output data resulting from the activity of the
neural net. Hardware nodes, which may comprise one or more chips,
microprocessors, integrated circuits, programmable logic
controllers, application-specific integrated circuits,
field-programmable gate arrays, or the like, may be provided to
optimize the speed, input/output efficiency, energy efficiency,
signal to noise ratio, or other parameter of some part of a neural
net of any of the types described herein. Hardware nodes may
include hardware for acceleration of calculations (such as
dedicated processors for performing basic or more sophisticated
calculations on input data to provide outputs, dedicated processors
for filtering or compressing data, dedicated processors for
decompressing data, dedicated processors for compression of
specific file or data types (e.g., for handling image data, video
streams, acoustic signals, vibration data, thermal images, heat
maps, or the like), and the like. A physical neural network may be
embodied in a data collector, such as a mobile data collector
described herein, including one that may be reconfigured by
switching or routing inputs in varying configurations, such as to
provide different neural net configurations within the data
collector for handling different types of inputs (with the
switching and configuration optionally under control of an expert
system, which may include a software-based neural net located on
the data collector or remotely). A physical, or at least partially
physical, neural network may include physical hardware nodes
located in a storage system, such as for storing data within an
industrial machine or in an industrial environment, such as for
accelerating input/output functions to one or more storage elements
that supply data to or take data from the neural net. A physical,
or at least partially physical, neural network may include physical
hardware nodes located in a network, such as for transmitting data
within, to or from an industrial environment, such as for
accelerating input/output functions to one or more network nodes in
the net, accelerating relay functions, or the like. In embodiments
of a physical neural network, an electrically adjustable resistance
material may be used for emulating the function of a neural
synapse. In embodiments, the physical hardware emulates the
neurons, and software emulates the neural network between the
neurons. In embodiments, neural networks complement conventional
algorithmic computers. They are versatile and can be trained to
perform appropriate functions without the need for any
instructions, such as classification functions, optimization
functions, pattern recognition functions, control functions,
selection functions, evolution functions, and others.
[0942] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
multilayered feed forward neural network, such as for complex
pattern classification of one or more items, phenomena, modes,
states, or the like. In embodiments, a multilayered feedforward
neural network may be trained by an optimization technical, such as
a genetic algorithm, such as to explore a large and complex space
of options to find an optimum, or near-optimum, global solution.
For example, one or more genetic algorithms may be used to train a
multilayered feedforward neural network to classify complex
phenomena, such as to recognize complex operational modes of
industrial machines, such as modes involving complex interactions
among machines (including interference effects, resonance effects,
and the like), modes involving non-linear phenomena, such as
impacts of variable speed shafts, which may make analysis of
vibration and other signals difficult, modes involving critical
faults, such as where multiple, simultaneous faults occur, making
root cause analysis difficult, and others. In embodiments, a
multilayered feed forward neural network may be used to classify
results from ultrasonic monitoring or acoustic monitoring of an
industrial machine, such as monitoring an interior set of
components within a housing, such as motor components, pumps,
valves, fluid handling components, and many others, such as in
refrigeration systems, refining systems, reactor systems, catalytic
systems, and others.
[0943] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
feedforward, back-propagation multi-layer perceptron (MLP) neural
network, such as for handling one or more remote sensing
applications, such as for taking inputs from sensors distributed
throughout various industrial environments. In embodiments, the MLP
neural network may be used for classification of physical
environments, such as mining environments, exploration
environments, drilling environments, and the like, including
classification of geological structures (including underground
features and above ground features), classification of materials
(including fluids, minerals, metals, and the like), and other
problems. This may include fuzzy classification.
[0944] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
structure-adaptive neural network, where the structure of a neural
network is adapted, such as based on a rule, a sensed condition, a
contextual parameter, or the like. For example, if a neural network
does not converge on a solution, such as classifying an item or
arriving at a prediction, when acting on a set of inputs after some
amount of training, the neural network may be modified, such as
from a feedforward neural network to a recurrent neural network,
such as by switching data paths between some subset of nodes from
unidirectional to bi-directional data paths. The structure
adaptation may occur under control of an expert system, such as to
trigger adaptation upon occurrence of a trigger, rule or event,
such as recognizing occurrence of a threshold (such as an absence
of a convergence to a solution within a given amount of time) or
recognizing a phenomenon as requiring different or additional
structure (such as recognizing that a system is varying dynamically
or in a non-linear fashion). In one non-limiting example, an expert
system may switch from a simple neural network structure like a
feedforward neural network to a more complex neural network
structure like a recurrent neural network, a convolutional neural
network, or the like upon receiving an indication that a
continuously variable transmission is being used to drive a
generator, turbine, or the like in a system being analyzed.
[0945] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use an
autoencoder, autoassociator or Diabolo neural network, which may be
similar to a multilayer perceptron ("MLP") neural network, such as
where there may be an input layer, an output layer and one or more
hidden layers connecting them. However, the output layer in the
auto-encoder may have the same number of units as the input layer,
where the purpose of the MLP neural network is to reconstruct its
own inputs (rather than just emitting a target value). Therefore,
the auto encoders may operate as an unsupervised learning model. An
auto encoder may be used, for example, for unsupervised learning of
efficient codings, such as for dimensionality reduction, for
learning generative models of data, and the like. In embodiments,
an auto-encoding neural network may be used to self-learn an
efficient network coding for transmission of analog sensor data
from an industrial machine over one or more networks. In
embodiments, an auto-encoding neural network may be used to
self-learn an efficient storage approach for storage of streams of
analog sensor data from an industrial environment.
[0946] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
probabilistic neural network ("PNN"), which in embodiments may
comprise a multi-layer (e.g., four-layer) feedforward neural
network, where layers may include input layers, hidden layers,
pattern/summation layers and an output layer. In an embodiment of a
PNN algorithm, a parent probability distribution function (PDF) of
each class may be approximated, such as by a Parzen window and/or a
non-parametric function. Then, using the PDF of each class, the
class probability of a new input is estimated, and Bayes' rule may
be employed, such as to allocate it to the class with the highest
posterior probability. A PNN may embody a Bayesian network and may
use a statistical algorithm or analytic technique, such as Kernel
Fisher discriminant analysis technique. The PNN may be used for
classification and pattern recognition in any of a wide range of
embodiments disclosed herein. In one non-limiting example, a
probabilistic neural network may be used to predict a fault
condition of an engine based on collection of data inputs from
sensors and instruments for the engine.
[0947] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
time delay neural network (TDNN), which may comprise a feedforward
architecture for sequential data that recognizes features
independent of sequence position. In embodiments, to account for
time shifts in data, delays are added to one or more inputs, or
between one or more nodes, so that multiple data points (from
distinct points in time) are analyzed together. A time delay neural
network may form part of a larger pattern recognition system, such
as using a perceptron network. In embodiments, a TDNN may be
trained with supervised learning, such as where connection weights
are trained with back propagation or under feedback. In
embodiments, a TDNN may be used to process sensor data from
distinct streams, such as a stream of velocity data, a stream of
acceleration data, a stream of temperature data, a stream of
pressure data, and the like, where time delays are used to align
the data streams in time, such as to help understand patterns that
involve understanding of the various streams (e.g., where increases
in pressure and acceleration occur as an industrial machine
overheats).
[0948] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
convolutional neural network (referred to in some cases as a CNN, a
ConvNet, a shift invariant neural network, or a space invariant
neural network), wherein the units are connected in a pattern
similar to the visual cortex of the human brain. Neurons may
respond to stimuli in a restricted region of space, referred to as
a receptive field. Receptive fields may partially overlap, such
that they collectively cover the entire (e.g., visual) field. Node
responses can be calculated mathematically, such as by a
convolution operation, such as using multilayer perceptrons that
use minimal preprocessing. A convolutional neural network may be
used for recognition within images and video streams, such as for
recognizing a type of machine in a large environment using a camera
system disposed on a mobile data collector, such as on a drone or
mobile robot. In embodiments, a convolutional neural network may be
used to provide a recommendation based on data inputs, including
sensor inputs and other contextual information, such as
recommending a route for a mobile data collector. In embodiments, a
convolutional neural network may be used for processing inputs,
such as for natural language processing of instructions provided by
one or more parties involved in a workflow in an environment. In
embodiments, a convolutional neural network may be deployed with a
large number of neurons (e.g., 100,000, 500,000 or more), with
multiple (e.g., 4, 5, 6 or more) layers, and with many (e.g.,
millions) parameters. A convolutional neural net may use one or
more convolutional nets.
[0949] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
regulatory feedback network, such as for recognizing emergent
phenomena (such as new types of faults not previously understood in
an industrial environment).
[0950] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
self-organizing map ("SOM"), involving unsupervised learning. A set
of neurons may learn to map points in an input space to coordinates
in an output space. The input space can have different dimensions
and topology from the output space, and the SOM may preserve these
while mapping phenomena into groups.
[0951] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
learning vector quantization neural net ("LVQ"). Prototypical
representatives of the classes may parameterize, together with an
appropriate distance measure, in a distance-based classification
scheme.
[0952] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use an
echo state network ("ESN"), which may comprise a recurrent neural
network with a sparsely connected, random hidden layer. The weights
of output neurons may be changed (e.g., the weights may be trained
based on feedback). In embodiments, an ESN may be used to handle
time series patterns, such as, in an example, recognizing a pattern
of events associated with a gear shift in an industrial turbine,
generator, or the like.
[0953] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
bi-directional, recurrent neural network ("BRNN"), such as using a
finite sequence of values (e.g., voltage values from a sensor) to
predict or label each element of the sequence based on both the
past and the future context of the element. This may be done by
adding the outputs of two RNNs, such as one processing the sequence
from left to right, the other one from right to left. The combined
outputs are the predictions of target signals, such as those
provided by a teacher or supervisor. A bi-directional RNN may be
combined with a long short-term memory RNN.
[0954] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
hierarchical RNN that connects elements in various ways to
decompose hierarchical behavior, such as into useful subprograms.
In embodiments, a hierarchical RNN may be used to manage one or
more hierarchical templates for data collection in an industrial
environment.
[0955] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
stochastic neural network, which may introduce random variations
into the network. Such random variations can be viewed as a form of
statistical sampling, such as Monte Carlo sampling.
[0956] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
genetic scale recurrent neural network. In such embodiments, a RNN
(often a LS.TM.) is used where a series is decomposed into a number
of scales where every scale informs the primary length between two
consecutive points. A first order scale consists of a normal RNN, a
second order consists of all points separated by two indices and so
on. The Nth order RNN connects the first and last node. The outputs
from all the various scales may be treated as a committee of
members, and the associated scores may be used genetically for the
next iteration.
[0957] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
committee of machines ("CoM"), comprising a collection of different
neural networks that together "vote" on a given example. Because
neural networks may suffer from local minima, starting with the
same architecture and training, but using randomly different
initial weights often gives different results. A CoM tends to
stabilize the result.
[0958] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use an
associative neural network ("ASNN"), such as involving an extension
of committee of machines that combines multiple feed forward neural
networks and a k-nearest neighbor technique. It may use the
correlation between ensemble responses as a measure of distance
amid the analyzed cases for the kNN. This corrects the bias of the
neural network ensemble. An associative neural network may have a
memory that can coincide with a training set. If new data become
available, the network instantly improves its predictive ability
and provides data approximation (self-learns) without retraining.
Another important feature of ASNN is the possibility to interpret
neural network results by analysis of correlations between data
cases in the space of models.
[0959] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use an
instantaneously trained neural network ("ITNN"), where the weights
of the hidden and the output layers are mapped directly from
training vector data.
[0960] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
spiking neural network, which may explicitly consider the timing of
inputs. The network input and output may be represented as a series
of spikes (such as a delta function or more complex shapes). SNNs
can process information in the time domain (e.g., signals that vary
over time, such as signals involving dynamic behavior of industrial
machines). They are often implemented as recurrent networks.
[0961] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
dynamic neural network that addresses nonlinear multivariate
behavior and includes learning of time-dependent behavior, such as
transient phenomena and delay effects. Transients may include
behavior of shifting industrial components, such as variable speeds
of rotating shafts or other rotating components.
[0962] In embodiments, cascade correlation may be used as an
architecture and supervised learning algorithm, supplementing
adjustment of the weights in a network of fixed topology.
Cascade-correlation may begin with a minimal network, then
automatically trains and adds new hidden units one by one, creating
a multi-layer structure. Once a new hidden unit has been added to
the network, its input-side weights may be frozen. This unit then
becomes a permanent feature-detector in the network, available for
producing outputs or for creating other, more complex feature
detectors. The cascade-correlation architecture may learn quickly,
determine its own size and topology, and retain the structures it
has built even if the training set changes and requires no
back-propagation.
[0963] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
neuro-fuzzy network, such as involving a fuzzy inference system in
the body of an artificial neural network. Depending on the type,
several layers may simulate the processes involved in a fuzzy
inference, such as fuzzification, inference, aggregation and
defuzzification. Embedding a fuzzy system in a general structure of
a neural net as the benefit of using available training methods to
find the parameters of a fuzzy system.
[0964] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
compositional pattern-producing network ("CPPN"), such as a
variation of an associative neural network ("ANN") that differs the
set of activation functions and how they are applied. While typical
ANNs often contain only sigmoid functions (and sometimes Gaussian
functions), CPPNs can include both types of functions and many
others. Furthermore, CPPNs may be applied across the entire space
of possible inputs, so that they can represent a complete image.
Since they are compositions of functions, CPPNs in effect encode
images at infinite resolution and can be sampled for a particular
display at whatever resolution is optimal.
[0965] This type of network can add new patterns without
re-training. In embodiments, methods and systems described herein
that involve an expert system or self-organization capability may
use a one-shot associative memory network, such as by creating a
specific memory structure, which assigns each new pattern to an
orthogonal plane using adjacently connected hierarchical
arrays.
[0966] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
hierarchical temporal memory ("HTM") neural network, such as
involving the structural and algorithmic properties of the
neocortex. HTM may use a biomimetic model based on
memory-prediction theory. HTM may be used to discover and infer the
high-level causes of observed input patterns and sequences.
[0967] In embodiments, methods and systems described herein that
involve an expert system or self-organization capability may use a
holographic associative memory ("HAM") neural network, which may
comprise an analog, correlation-based, associative,
stimulus-response system. Information may be mapped onto the phase
orientation of complex numbers. The memory is effective for
associative memory tasks, generalization and pattern recognition
with changeable attention.
[0968] In embodiments, various embodiments involving network coding
may be used to code transmission data among network nodes in neural
net, such as where nodes are located in one or more data collectors
or machines in an industrial environment.
[0969] Clause 1. In embodiments, an expert system for processing a
plurality of inputs collected from sensors in an industrial
environment, comprising: A modular neural network, where the expert
system uses one type of neural network for recognizing a pattern
and a different neural network for self-organizing an activity in
the industrial environment. 2. A system of clause 1, wherein the
pattern indicates a fault condition of a machine. 3. A system of
clause 1, wherein the self-organized activity governs autonomous
control of a system in the environment. 4. A system of clause 3,
wherein the expert system organizes the activity based at least in
part on the recognized pattern. 5. An expert system for processing
a plurality of inputs collected from sensors in an industrial
environment, comprising:
a modular neural network, where the expert system uses one neural
network for classifying an item and a different neural network for
predicting a state of the item. 6. A system of clause 5, wherein
classifying an item includes at least one of identifying a machine,
a component, and an operational mode of a machine in the
environment. 7. A system of clause 5, wherein predicting a state
includes predicting at least one of a fault state, an operational
state, an anticipated state, and a maintenance state. 8. An expert
system for processing a plurality of inputs collected from sensors
in an industrial environment, comprising: a modular neural network,
where the expert system uses one neural network for determining at
least one of a state and a context and a different neural network
for self-organizing a process involving the at least one state or
context. 9. A system of clause 8, wherein the stat or context
includes at least one state of a machine, a process, a work flow, a
marketplace, a storage system, a network, and a data collector. 10.
A system of clause 8, wherein the self-organized process includes
at least one of a data storage process, a network coding process, a
network selection process, a data marketplace process, a power
generation process, a manufacturing process, a refining process, a
digging process, and a boring process. 11. An expert system for
processing a plurality of inputs collected from sensors in an
industrial environment, comprising: a modular neural network,
comprising at least two neural networks selected from the group
consisting of feed forward neural networks, radial basis function
neural networks, self-organizing neural networks, Kohonen
self-organizing neural networks, recurrent neural networks, modular
neural networks, artificial neural networks, physical neural
networks, multi-layered neural networks, convolutional neural
networks, a hybrids of a neural networks with another expert
system, auto-encoder neural networks, probabilistic neural
networks, time delay neural networks, convolutional neural
networks, regulatory feedback neural networks, radial basis
function neural networks, recurrent neural networks, Hopfield
neural networks, Boltzmann machine neural networks, self-organizing
map ("SOM") neural networks, learning vector quantization ("LVQ")
neural networks, fully recurrent neural networks, simple recurrent
neural networks, echo state neural networks, long short-term memory
neural networks, bi-directional neural networks, hierarchical
neural networks, stochastic neural networks, genetic scale RNN
neural networks, committee of machines neural networks, associative
neural networks, physical neural networks, instantaneously trained
neural networks, spiking neural networks, neocognition neural
networks, dynamic neural networks, cascading neural networks,
neuro-fuzzy neural networks, compositional pattern-producing neural
networks, memory neural networks, hierarchical temporal memory
neural networks, deep feed forward neural networks, gated recurrent
unit ("GCU") neural networks, auto encoder neural networks,
variational auto encoder neural networks, de-noising auto encoder
neural networks, sparse auto-encoder neural networks, Markov chain
neural networks, restricted Boltzmann machine neural networks, deep
belief neural networks, deep convolutional neural networks,
deconvolutional neural networks, deep convolutional inverse
graphics neural networks, generative adversarial neural networks,
liquid state machine neural networks, extreme learning machine
neural networks, echo state neural networks, deep residual neural
networks, support vector machine neural networks, neural Turing
machine neural networks, and holographic associative memory neural
networks. 12. A system for collecting data in an industrial
environment, comprising A physical neural network embodied in a
mobile data collector, wherein the mobile data collector is adapted
to be reconfigured by routing inputs in varying configurations,
such that different neural net configurations are enabled within
the data collector for handling different types of inputs. 13. A
system of clause 12, wherein reconfiguration occurs under control
of an expert system. 14. A system of clause 13, wherein the expert
system includes a software-based neural net. 15. A system of clause
14, wherein the software-based system is located on the data
collector. 16. A system of clause 14, wherein the software-based
system is located remotely from the data collector. 17. A system
for processing data collected from an industrial environment, the
system comprising: a plurality of neural networks deployed in a
cloud platform that receives data streams and other inputs
collected from one or more industrial environments and transmitted
to the cloud platform over one or more networks, wherein the neural
networks are of different types. 18. A system of clause 17, wherein
the plurality of neural networks includes at least one modular
neural network. 19. A system of clause 17, wherein the plurality of
neural networks includes at least one structure-adaptive neural
network. 20. A system of clause 17, wherein the neural networks are
structured to compete with each other under control of an expert
system, such as by processing input data sets from the same
industrial environment to provide outputs and comparing the outputs
to at least one measure of success. 21. A system of clause 20,
wherein a genetic algorithm is used to facilitate variation and
selection for the competing neural networks. 22. A system of clause
20, wherein the measure of success includes at least one of the
following measures: a measure of predictive accuracy, a measure of
classification accuracy, an efficiency measure, a profit measure, a
maintenance measure, a safety measure, and a yield measure. 23. A
system, comprising: a network coding system for coding transmission
of data among network nodes in neural network, wherein the nodes
comprise hardware devices located in at least one of one or more
data collectors, one or more storage systems, and one or more
network devices located in an industrial environment.
[0970] Within the data collection, monitoring, and control
environment of the industrial IoT are large and various sensor
sets, which make efficient setup and timely changes to sensor data
collection a challenge. Continuous collection from all sensors may
be impossible given the large number of sensors and limited
resources, such as limited availability of power and limited data
collection and management facilities, including various limitations
in availability and performance of sensor data collection devices,
input/output interfaces, data transfer facilities, data storage,
data analysis facilities, and the like. The number of sensors
collected from at any given time must therefore be limited in an
intelligent but timely manner, both at the time of setting up
initial collection and during the process of collection, including
handling rapid changes to a present collection scheme based on a
change in state of a system, operational conditions (e.g., an alert
condition, change in operational mode, etc.), or the like.
Embodiments of the methods and systems disclosed herein may
therefore include rapid route creation and modification for routing
collectors, such as by taking advantage of hierarchical templates,
execution of smart route changes, monitoring and responding to
changes in operational conditions, and the like.
[0971] In embodiments, rapid route creation and modification for
data collection in an industrial environment may take advantage of
hierarchical templates. Templates may be used to take advantage of
`like` machinery that can utilize the same hierarchical sensor
routing scheme. For example, among many possible types of machines
about which data may be collected, the members of a certain class
of motor, such as a stepper motor class, may have very similar
sensor routing needs, such as for routine operations, routine
maintenance, and failure mode detection, that may be described in a
common hierarchy of sensor collection routines. The user installing
a new stepper motor may then use the `stepper motor hierarchical
routing template` for the new motor. After installation, the
stepper motor hierarchical routing template may then be used to
change the routing schemes for changing conditions. The user may
optionally make adjustments to the template as needed per unique
motor functions, applications, environments, modes, and the like.
The use of a template for deploying a routing scheme greatly
reduces the time a user requires to configure the routing scheme
for a new motor, or to deploy new routing technologies on an
existing system that utilizes traditional sensor collection
methods. Once the hierarchical routing template is in place, the
sensor collection routine may be changed quickly based on the
template, thus allowing for rapid route modification under changing
conditions, such as: a change in the operating mode of the stepper
motor that requires a different subset of sensors for monitoring, a
limit alert or failure indication that requires a more focused
subset of sensors for use in diagnosing the problem, and the like.
Hierarchical routing templates thus allow for rapid deployment of
sensor routing configurations, as well as allowing the sensed
industrial environment to be altered dynamically as conditions
change.
[0972] A functional hierarchy of routing templates may include
different hierarchical configurations for a component, machine,
system, industrial environment, and the like, including all sensors
and a plurality of configurations formed from a subset of all
sensors. At a system level, an `all-sensor` configuration may
include: a connection map to all sensors in a system, mapping to
all onboard instrumentation sensors (e.g., monitoring points
reporting within a machine or set of machines), mapping to an
environment's sensors (e.g., monitoring points around the
machines/equipment, but not necessarily onboard), mapping to
available sensors on data collectors (e.g., data collectors that
can be flexibly provisioned for particular data among different
kinds), a unified map combining different individual mappings, and
the like. A routing configuration may be provided, such as to
indicate how to implement an operational routing scheme, a
scheduled maintenance routing scheme (e.g., collecting from a
greater set of overall sensors than in operational mode, but
distributed across the system, or a focused sensor set for specific
components, functions, and modes), one or more failure mode routing
schemes for multiple focused sensor collection groups targeting
different failure mode analyses (e.g., for a motor, one failure
mode may be for bearings, another for startup speed-torque, where a
different subset of sensor data is needed based on the failure
mode, such as detected in anomalous readings taken during
operations or maintenance), power savings (e.g., weather conditions
necessitating reduced plant power), and the like.
[0973] As noted, hierarchical templates may also be conditional
(e.g., rule-based), such as templates with conditional routing
based on parameters, such as sensed data during a first collection
period, where a subsequent routing configuration is varied. Within
the hierarchy, nodes in a graph or tree may indicate forks by which
conditional logic may be used, such as to select a given subset of
sensors for a given operational mode. Thus, the hierarchical
template may be associated with a rule-based or model-based expert
system, which may facilitate automated routing based on the
hierarchical template and based on observed conditions, such as
based on a type of machine and its operational state, environmental
context, or the like. In a non-limiting example, a hierarchical
template may have an initial collection configuration and a
conditional hierarchy in place to switch from the initial
collection configuration to a second collection configuration based
on the sensed conditions of an initial sensor collection.
Continuing this example, among various possible machines, a
conveyor system may have a plurality of sensors for collection in
an initial collection, but once the first data is collected and
analyzed, if the conveyor is determined to be in an idle state
(such as due to the absence of a signal above a minimum threshold
on a motion sensor), then the system may switch to a sensor data
collection regime that is appropriate for the idles state of the
conveyor (e.g., using a very small subset of the plurality of
sensors, such as just using the motion sensor to detect departure
from the idle state, at which point the original regime may be
renewed and the rest of a sensor set may be re-engaged). Thus, when
the collection of sensor data detects a changed condition to a
state, an operational mode, an environmental condition, or the
like, the sensor data collection may be switched to an appropriate
configuration.
[0974] Hierarchical templates for one collector may be based on
coordination of routing with that of other collectors. For
instance, a collector might be set up to perform vibration analysis
while another collector is set up to perform pressure or
temperature on each machine in a set of similar machines, rather
than having each machine collect all of the data on each machine,
where otherwise setup for different sensor types may be required
for each collector for each machine. Factors such as the duration
of sampling required, the time required to set up a given sensor,
the amount of power consumed, the time available for collection as
a whole, the data rate of input/output of a sensor and/or the
collector, the bandwidth of a channel (wired or wireless) available
for transmission of collected data, and the like can be considered
in arranging the coordination of the routing of two or more
collectors, such that various parallel and serial configurations
may be undertaken to achieve an overall effectiveness. This may
include optimizing the coordination using an expert system, such as
a rule-based optimization, a model-based optimization, or
optimization using machine learning.
[0975] A machine learning system may create a hierarchical template
structure for improved routing, such as for teaching the system the
default operating conditions (e.g., normal operations mode, systems
online and average production), peak operations mode (max
capability), slack production, and the like. The machine learning
system may create a new hierarchical template based on monitored
conditions, such as a template based on a production level profile,
a rate of production profile, a detected failure mode pattern
analysis, and the like. The application of a new machine learning
created template may be based on a mode matching between current
production conditions and a machine learning template condition
(e.g., the machine learning system creates a new template for a new
production profile, and applies that new template whenever that new
profile is detected).
[0976] Rapid route creation may be enabled using one or more
hierarchical routing templates, such as when a routing template
pre-establishes a routing scheme for different conditions, and when
a trigger event executes a change in the sensor routing scheme to
accommodate the condition. In embodiments, the trigger event may be
an automatic change in routing based on a trigger that indicates a
possible failure mode that forces a change in routing scheme from
operational to failure mode analysis; a human-executed change in
routing scheme based on received sensor data; a learned routing
change based on machine learning of when to trigger a change (e.g.,
as based on a machine being fed with a set of human-executed or
human-supervised changes); a manual routing change (e.g., optional
to automatic/rapid automatic change); a human executed change based
on observed device performance; and the like. Routing changes may
include: changing from an operational mode to an accelerated
maintenance, a failure mode analysis, a power saving mode a
high-performance/high-output mode (e.g., for peak power in a
generation plant), and the like.
[0977] Switching hierarchical template configurations may be
executed based on connectivity with end-device sensors. In a highly
automated collection routing environment (e.g., an indoor networked
assembly plant) different routing collection configurations may be
employed for fixed and flexible industrial layouts. In a fixed
industrial layout, such as a layout with a high degree of wired
connectivity between end-device sensors, automated collectors, and
networks, there may be different routing configurations for a
network routing hierarchy portion, a collector sensor-collection
hierarchy portion, a storage portion, and the like. For a more
flexible industrial layout with various wired and wireless
connections between end-device sensors, automated collectors, and
networks, there may be different schemes. For instance, a
moderately automated collection routing environment may include:
automatic collection and periodic network connection; a
robot-carried collector for periodic collection (e.g., a
ground-based robot, a drone, an underwater device, a robot with
network connection, a robot with intermittent network connection, a
robot that periodically uploads collection); a routing scheme with
periodic collection and automated routing; a scheme only collecting
periodically but routed directly upon collection; a routing scheme
with periodic collection and periodic automated routing to collect
periodically; and, over longer periods of time, periodically
routing multiple collections; and the like. For a lower degree of
automated collection routing, there may be a combination of:
automatic collection and human-aided collectors (e.g., humans
collecting alone, humans aided by robots), scheduled collection and
human-aided collectors (e.g., humans initiating collection, humans
aided by robots for collection initiation, human launching a drone
to collect data at a remote site), and the like.
[0978] In embodiments, and referring to FIG. 137, hierarchical
templates may be utilized by a local data collection system 10500
for collection and monitoring of data collected through a plurality
of input channels 10500, such as data from sensors 10514, IoT
devices 10516, and the like. The local collection system 10512,
also referred to herein as a data collector 10512, may comprise a
data storage 10502; a data acquisition circuit 10504; a data
analysis circuit 10506; and the like, wherein the monitoring
facilities may be deployed: locally on the data collector 10512; in
part locally on the data collector and in part on a remote
information technology infrastructure component apart from the data
collector; and the like. A monitoring system may comprise a
plurality of input channels communicatively coupled to the data
collector 10512. The data storage 10502 may be structured to store
a plurality of collector route templates 10510 and sensor
specifications for sensors 10514 that correspond to the input
channels 10500, wherein the plurality of collector route templates
10510 each comprise a different sensor collection routine. A data
acquisition circuit 10504 may be structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of the input channels 10500,
and a data analysis circuit 10506 structured to receive output data
from the plurality of input channels 10500 and evaluate a current
routing template collection routine based on the received output
data, wherein the data collector 10500 is configured to switch from
the current routing template collection routine to an alternative
routing template collection routine based on the content of the
output data. The monitoring system may further utilize a machine
learning system (e.g., a neural network expert system), rule-based
templates (e.g., based on an operational state of a machine with
respect to which the input channels provide information, the input
channels provide information, the input channels provide
information), smart route changes, alarm states, network
connectivity, self-organization amongst a plurality of data
collectors, coordination of sensor groups, and the like.
[0979] In embodiments, evaluation of the current routing templates
may be based on operational mode routing collection schemes, such
as a normal operational mode, a peak operational mode, an idle
operational mode, a maintenance operational mode, a power saving
operational mode, and the like. As a result of monitoring, the data
collector may switch from a current routing template collection
routine because the data analysis circuit determines a change in
operating modes, such as the operating mode changing from an
operational mode to an accelerated maintenance mode, the operating
mode changing from an operational mode to a failure mode analysis
mode, the operating mode changing from an operational mode to a
power-saving mode, the operating mode changing from an operational
mode to a high-performance mode, and the like. The data collector
may switch from a current routing template collection routine based
on a sensed change in a mode of operation, such as a failure
condition, a performance condition, a power condition, a
temperature condition, a vibration condition, and the like. The
evaluation of the current routing template collection routine may
be based on a collection routine with respect to a collection
parameter, such as network availability, sensor availability, a
time-based collection routine (e.g., on a schedule, over time), and
the like.
[0980] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collector
communicatively coupled to a plurality of input channels; a data
storage structured to store a plurality of collector route
templates and sensor specifications for sensors that correspond to
the input channels, wherein the plurality of collector route
templates each comprise a different sensor collection routine; a
data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels; and a data
analysis circuit structured to receive output data from the
plurality of input channels and evaluate a current routing template
collection routine based on the received output data, wherein the
data collector is configured to switch from the current routing
template collection routine to an alternative routing template
collection routine based on the content of the output data. In
embodiments, the system is deployed locally on the data collector,
in part locally on the data collector and in part on a remote
information technology infrastructure component apart from the
collector, and the like. Each of the input channels may correspond
to a sensor located in the environment. The evaluation of the
current routing template may be based on operational mode routing
collection schemes. The operational mode is at least one of a
normal operational mode, a peak operational mode, an idle
operational mode, a maintenance operational mode, and a power
saving operational mode. The data collector may switch from the
current routing template collection routine because the data
analysis circuit determines a change in operating modes, such as
where the operating mode changes from an operational mode to an
accelerated maintenance mode, from an operational mode to a failure
mode analysis mode, from an operational mode to a power saving
mode, from an operational mode to high-performance mode, and the
like. The data collector may switch from the current routing
template collection routine based on a sensed change in a mode of
operation, such as where the sensed change is a failure condition,
a performance condition, a power condition, a temperature
condition, a vibration condition, and the like. The evaluation of
the current routing template collection routine may be based on a
collection routine with respect to a collection parameter, such as
where the parameter is network availability, sensor availability, a
time-based collection routine (e.g., where a routine collects
sensor data on a schedule, evaluates sensor data over time).
[0981] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data storage structured to store a plurality of collector route
templates and sensor specifications for sensors that correspond to
the input channels, wherein the plurality of collector route
templates each comprise a different sensor collection routine;
providing a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of the input channels; and
providing a data analysis circuit structured to receive output data
from the plurality of input channels and evaluate a current routing
template collection routine based on the received output data,
wherein the data collector is configured to switch from the current
routing template collection routine to an alternative routing
template collection routine based on the content of the output
data. In embodiments, the computer-implemented method is deployed
locally on the data collector, such as deployed in part locally on
the data collector and in part on a remote information technology
infrastructure component apart from the collector, where each of
the input channels correspond to a sensor located in the
environment.
[0982] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a data collector communicatively coupled to a
plurality of input channels; providing a data storage structured to
store a plurality of collector route templates and sensor
specifications for sensors that correspond to the input channels,
wherein the plurality of collector route templates each comprise a
different sensor collection routine; providing a data acquisition
circuit structured to interpret a plurality of detection values,
each of the plurality of detection values corresponding to at least
one of the input channels; and providing a data analysis circuit
structured to receive output data from the plurality of input
channels and evaluate a current routing template collection routine
based on the received output data, wherein the data collector is
configured to switch from the current routing template collection
routine to an alternative routing template collection routine based
on the content of the output data. In embodiments, the instructions
may be deployed locally on the data collector, such as deployed in
part locally on the data collector and in part on a remote
information technology infrastructure component apart from the
collector, where each of the input channels correspond to a sensor
located in the environment.
[0983] In embodiments, a monitoring system for data collection in
an industrial environment may comprise a data collector
communicatively coupled to a plurality of input channels; a data
storage structured to store a plurality of collector route
templates, sensor specifications for sensors that correspond to the
input channels, wherein the plurality of collector route templates
each comprise a different sensor collection routine; a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels; and a machine
learning data analysis circuit structured to receive output data
from the plurality of input channels and evaluate a current routing
template collection routine based on the received output data
received over time, wherein the machine learning data analysis
circuit learns received output data patterns, wherein the data
collector is configured to switch from the current routing template
collection routine to an alternative routing template collection
routine based on the learned received output data patterns. In
embodiments, the monitoring system may be deployed locally on the
data collector, such as deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, where each of
the input channels correspond to a sensor located in the
environment. The machine learning data analysis circuit may include
a neural network expert system. The evaluation of the current
routing template may be based on operational mode routing
collection schemes. The operational mode may be at least one of a
normal operational mode, a peak operational mode, an idle
operational mode, a maintenance operational mode, and a power
saving operational mode. The data collector may switch from the
current routing template collection routine because the data
analysis circuit determines a change in operating modes, such as
where the operating mode changes from an operational mode to an
accelerated maintenance mode, from an operational mode to a failure
mode analysis mode, from an operational mode to a power saving
mode, from an operational mode to high-performance mode, and the
like. The data collector may switch from the current routing
template collection routine based on a sensed change in a mode of
operation, such as where the sensed change is a failure condition,
a performance condition, a power condition, a temperature
condition, a vibration condition, and the like. The evaluation of
the current routing template collection routine may be based on a
collection routine with respect to a collection parameter, such as
where the parameter is network availability, a sensor availability,
a time-based collection routine (collects sensor data on a
schedule, evaluates sensor data over time).
[0984] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data storage structured to store a plurality of collector route
templates, sensor specifications for sensors that correspond to the
input channels, wherein the plurality of collector route templates
each comprise a different sensor collection routine; providing a
data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels; and providing
a machine learning data analysis circuit structured to receive
output data from the plurality of input channels and evaluate a
current routing template collection routine based on the received
output data received over time, wherein the machine learning data
analysis circuit learns received output data patterns, wherein the
data collector is configured to switch from the current routing
template collection routine to an alternative routing template
collection routine based on the learned received output data
patterns. In embodiments, the method may be deployed locally on the
data collector, such as deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, where each of
the input channels correspond to a sensor located in the
environment.
[0985] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a data collector communicatively coupled to a
plurality of input channels; providing a data storage structured to
store a plurality of collector route templates, sensor
specifications for sensors that correspond to the input channels,
wherein the plurality of collector route templates each comprise a
different sensor collection routine; providing a data acquisition
circuit structured to interpret a plurality of detection values,
each of the plurality of detection values corresponding to at least
one of the input channels; and providing a machine learning data
analysis circuit structured to receive output data from the
plurality of input channels and evaluate a current routing template
collection routine based on the received output data received over
time, wherein the machine learning data analysis circuit learns
received output data patterns, wherein the data collector is
configured to switch from the current routing template collection
routine to an alternative routing template collection routine based
on the learned received output data patterns. In embodiments, the
instructions may be deployed locally on the data collector, such as
deployed in part locally on the data collector and in part on a
remote information technology infrastructure component apart from
the collector, where each of the input channels correspond to a
sensor located in the environment.
[0986] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collector
communicatively coupled to a plurality of input channels; a data
storage structured to store a collector route template, sensor
specifications for sensors that correspond to the input channels,
wherein the collector route template comprises a sensor collection
routine; a data acquisition circuit structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of the input channels; and a
data analysis circuit structured to receive output data from the
plurality of input channels and evaluate the received output data
with respect to a rule, wherein the data collector is configured to
modify the sensor collection routine based on the application of
the rule to the received output data. In embodiments, the system
may be deployed locally on the data collector, such as deployed in
part locally on the data collector and in part on a remote
information technology infrastructure component apart from the
collector, where each of the input channels correspond to a sensor
located in the environment. The rule may be based on an operational
state of a machine with respect to which the input channels provide
information, on an anticipated state of a machine with respect to
which the input channels provide information, on a detected fault
condition of a machine with respect to which the input channels
provide information, and the like. The evaluation of the received
output data may be based on operational mode routing collection
schemes, where the operational mode is at least one of a normal
operational mode, a peak operational mode, an idle operational
mode, a maintenance operational mode, and a power saving
operational mode. The data collector may modify the sensor
collection routine because the data analysis circuit determines a
change in operating modes, such as where the operating mode changes
from an operational mode to an accelerated maintenance mode, from
an operational mode to a failure mode analysis mode, from an
operational mode to a power saving mode, from an operational mode
to high-performance mode, and the like. The data collector may
modify the sensor collection routine based on a sensed change in a
mode of operation, such as where the sensed change is a failure
condition, a performance condition, a power condition, a
temperature condition, a vibration condition, and the like. The
evaluation of the received output data may be based on a collection
routine with respect to a collection parameter, wherein the
parameter is a network availability, a sensor availability, a
time-based collection routine (e.g., collects sensor data on a
schedule or over time), and the like.
[0987] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data storage structured to store a collector route template,
sensor specifications for sensors that correspond to the input
channels, wherein the collector route template comprises a sensor
collection routine; providing a data acquisition circuit structured
to interpret a plurality of detection values, each of the plurality
of detection values corresponding to at least one of the input
channels; and providing a data analysis circuit structured to
receive output data from the plurality of input channels and
evaluate the received output data with respect to a rule, wherein
the data collector is configured to modify the sensor collection
routine based on the application of the rule to the received output
data. In embodiments, the method may be deployed locally on the
data collector, such as deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, where each of
the input channels correspond to a sensor located in the
environment.
[0988] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a data collector communicatively coupled to a
plurality of input channels; providing a data storage structured to
store a collector route template, sensor specifications for sensors
that correspond to the input channels, wherein the collector route
template comprises a sensor collection routine; providing a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels; and providing
a data analysis circuit structured to receive output data from the
plurality of input channels and evaluate the received output data
with respect to a rule, wherein the data collector is configured to
modify the sensor collection routine based on the application of
the rule to the received output data. In embodiments, the
instructions may be deployed locally on the data collector, such as
deployed in part locally on the data collector and in part on a
remote information technology infrastructure component apart from
the collector, where each of the input channels correspond to a
sensor located in the environment.
[0989] Rapid route creation and modification in an industrial
environment may employ smart route changes based on incoming data
or alarms, such as changes enabling dynamic selection of data
collection for analysis or correlation. Smart route changes may
enable the system to alter current routing of sensor data based on
incoming data or alarms. For instance, a user may set up a routing
configuration that establishes a schedule of sensor collection for
analysis, but when the analysis (or an alarm) indicates a special
need, the system may change the sensor routing to address that
need. For example, in the case where a change in a motor vibration
profile (as one example among any of the machines described
throughout this disclosure), such as rapidly increasing the peak
amplitude of shaking on at least one axis of a vibration sensor
set, that indicates a potential early failure of the motor, the
system may change the routing to collect more focused data
collection for analysis, such as initiating collection on more axes
of the motor, initiating collection on additional bearings of the
motor, and/or initiating collection using other sensors (such as
temperature or heat flux sensors), that may confirm an initial
hypothesis that the failure mode is occurring or otherwise assist
in analysis of the state or operational condition of the
machine.
[0990] Detected operational mode changes may trigger a rapid route
change. For instance, an operational mode may be detected as the
result of a single-point sensor out-of-range detection, an analysis
determination, and the like, and generate a routing change. An
analysis determination may be detected from a sensor end-point,
such as through a single-point sensor analysis, a multiple-point
sensor analysis, an analysis domain analysis (e.g., through a time
profile, frequency profile, correlated multi-point determination),
and the like. In another instance, a maintenance mode may be
detected during routine maintenance, where a routing change
increases data collection to capture data at a higher rate under an
anomalous condition. A failure mode may be detected, such as
through an alarm that indicates near-term potential for a failure
of a machine that triggers increased data capture rate for
analysis. Performance-based modes may be detected, such as
detecting a level of output rate (e.g., peak, slack, idle), which
may then initiate changes in routing to accommodate the analysis
needs for the different performance monitoring and metrics
associated with the state. For example, if a high peak speed is
detected for a motor, a conveyor, an assembly line, a generator, a
turbine, or the like, relative to historical measurements over some
time period, additional sensors may be engaged to watch for
failures that are typically associated with peak speeds, such as
overheating (as measured by engaging a temperature or heat flux
sensor), excessive noise (as measured by an acoustic or noise
sensor), excessive shaking (as measured by one or more vibration
sensors), or the like.
[0991] Alarm detections may trigger a rapid route change. Alarm
sources may include a front-end collector, local intelligence
resource, back-end data analysis process, ambient environment
detector, network quality detector, power quality detector, heat,
smoke, noise, flooding, and the like. Alarm types may include a
single-instance anomaly detection, multiple-instance anomaly
detection, simultaneous multi-sensor detection, time-clustered
sensor detection (e.g., a single sensor or multiple sensors),
frequency-profile detection (e.g., increasing rate of anomaly
detection such as an alarm increasing in its occurrence over time,
a change in a frequency component of a sensor output such as a
motor's physical vibration profile changing over time), and the
like.
[0992] A machine learning system may change routing based on
learned alarm pattern analysis. The machine learning system may
learn system alarm condition patterns, such as alarm conditions
expected under normal operating conditions, under peak operating
conditions, expected over time based on age of components (e.g.,
new, during operational life, during extended life, during a
warrantee period), and the like. The machine learning system may
change routing based on a change in an alarm pattern, such as a
system operating normally but experiencing a peak operating alarm
pattern (e.g., a system running when it should not be), a system is
new but experiencing an older profile (e.g., detection of infant
mortality), and the like. The machine learning system may change
routing based on a current alarm profile vs. an expected change in
production condition. For example, a plant, system, or component is
experiencing above average alarm conditions just before a ramp-up
of production (e.g., could be foretelling of above average failures
during increased production), just before going slack (e.g., could
be an opportunity to ramp up maintenance procedures based on
increased data taking routing scheme), after an unplanned event
(e.g., weather, power outage, restart), and the like.
[0993] A rapid route change action may include: an increased rate
of sampling (e.g., to a single sensor, to multiple sensors), an
increase in the number of sensors being sampled (e.g., simultaneous
sampling of other sensors on a device, coordinated sampling of
similar sensors on near-by devices), generating a burst of sampling
(e.g., sampling at a high rate for a period of time), and the like.
Actions may be executed on a schedule, coordinated with a trigger,
based on an operational mode, and the like. Triggered actions may
include: anomalous data, an exceeded threshold level, an
operational event trigger (e.g., at startup condition such as for
startup motor torque), and the like.
[0994] A rapid route change may switch between routing schemes,
such as an operational routing scheme (e.g., a subset of sensor
collection for normal operations), a scheduled maintenance routing
scheme (e.g., an increased and focused set of sensor collection
than for normal operations), and the like. The distribution of
sensor data may be changed, such as to distribute sensor collection
across the system, such as for a sensor collection set for specific
components, functions, and modes. A failure mode routing scheme may
entail multiple focused sensor collection groups targeting
different failure mode analyses (e.g., for a motor, one failure
mode may be for bearings, another for startup speed-torque) where a
different subset of sensor data may be needed based on the failure
mode (e.g., as detected in anomalous readings taken during
operations or maintenance). Power saving mode routing may be
executed when weather conditions necessitate reduced plant
power.
[0995] Dynamic adjustment of route changes may be executed based on
connectivity factors, such as the factors associated with the
collector or network availability and bandwidth. For example,
routing may be changed for a device associated with an alarm
detection, where changing routing for targeted devices on the
network frees up bandwidth. Changes to routing may have a duration,
such as only for a pre-determined period of time and then switching
back, maintaining a change until user-directed, changing duration
based on network availability, and the like.
[0996] In embodiments, and referring to FIG. 139, smart route
changes may be implemented by a local data collection system 10520
for collection and monitoring of data collected through a plurality
of input channels 10500, such as data from sensors 10522, IoT
devices 10524, and the like. The local collection system 102, also
referred to herein as a data collector 10520, may comprise a data
storage 10502, a data acquisition circuit 10504, a data analysis
circuit 10506, a response circuit 10508, and the like, wherein the
monitoring facilities may be deployed locally on the data collector
10520, in part locally on the data collector and in part on a
remote information technology infrastructure component apart from
the data collector, and the like. Smart route changes may be
implemented between data collectors, such as where a state message
is transmitted between the data collectors (e.g., from an input
channel that is mounted in proximity to a second input channel,
from a related group of input sensors, and the like). A monitoring
system may comprise a plurality of input channels 10500
communicatively coupled to the data collector 10520. The data
acquisition circuit 10504 may be structured to interpret a
plurality of detection values, each of the plurality of detection
values corresponding to at least one of the input channels 10500,
wherein the data acquisition circuit 10504 acquires sensor data
from a first route of input channels for the plurality of input
channels. The data storage 10502 may be structured to store sensor
data, sensor specifications, and the like, for sensors 10524 that
correspond to the input channels 10500. The data analysis circuit
10506 may be structured to evaluate the sensor data with respect to
stored anticipated state information, wherein the anticipated state
information may include an alarm threshold level, and wherein the
data analysis circuit 10506 sets an alarm state when the alarm
threshold level is exceeded for a first input channel in the first
group of input channels. Further, the data analysis circuit 10506
may transmit the alarm state across a network to a routing control
facility 10512. The response circuit 10508 may be structured to
change the routing of the input channels for data collection from
the first routing of input channels to an alternate routing of
input channels upon reception of a routing change indication from
the routing control facility. In the case of a network
transmission, the alternate routing of input channels may include
the first input channel and a group of input channels related to
the first input channel, where the data collector executes the
change in routing of the input channels if a communication
parameter of the network between the data collector and the routing
control facility is not met (e.g., a time-period parameter, a
network connection and/or bandwidth availability parameter).
[0997] In embodiments, an alarm state may indicate a detection
mode, such as an operational mode detection comprising an
out-of-range detection, a maintenance mode detection comprising an
alarm detected during maintenance, a failure mode detection (e.g.,
where the controller communicates a failure mode detection
facility), a power mode detection wherein the alarm state is
indicative of a power related limitation data of the anticipated
state information, a performance mode detection wherein the alarm
state is indicative of a high-performance limitation data of the
anticipated state information, and the like. The monitoring system
may further include the analysis circuit setting the alarm state
when the alarm threshold level is exceeded for an alternate input
channel in the first group of input channels, such as where the
setting of the alarm state for the first input channel and the
alternate input channel are determined to be a multiple-instance
anomaly detection, wherein the second routing of input channels
comprises the first input channel and a second input channel,
wherein the sensor data from the first input channel and the second
input channel contribute to simultaneous data analysis. The second
routing of input channels may include a change in a routing
collection parameter, such as where the routing collection
parameter is an increase in sampling rate, an increase in the
number of channels being sampled, a burst sampling of at least one
of the plurality of input channels, and the like.
[0998] In embodiments, and referring to FIG. 138, collector route
templates 10510 may be utilized for smart route changes and may be
implemented by a local data collection system 10512 for collection
and monitoring of data collected through a plurality of input
channels 10500, such as data from sensors 10514, IoT devices 10516,
and the like. The local collection system 10512, also referred to
herein as a data collector 10512, may comprise a data storage
10502, a data acquisition circuit 10504, a data analysis circuit
10506, a response circuit 10508, and the like, wherein the
monitoring facilities may be deployed locally on the data collector
10512, in part locally on the data collector and in part on a
remote information technology infrastructure component apart from
the data collector, and the like.
[0999] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collector
communicatively coupled to a plurality of input channels; a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels for the plurality of input channels; a data storage
structured to store sensor specifications for sensors that
correspond to the input channels; a data analysis circuit
structured to evaluate the sensor data with respect to stored
anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channels; and a response circuit structured to change the
routing of the input channels for data collection from the first
routing of input channels to an alternate routing of input
channels, wherein the alternate routing of input channels comprise
the first input channel and a group of input channels related to
the first input channel. In embodiments, the system may be deployed
locally on the data collector, deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, wherein each of
the input channels correspond to a sensor located in the
environment. The group of input channels may be related to the
first input channel are at least in part taken from the plurality
of input channels not included in the first routing of input
channels. An alarm state may indicate a detection mode, such as
where the detection mode is an operational mode detection
comprising an out-of-range detection, the detection mode is a
maintenance mode detection comprising an alarm detected during
maintenance, the detection mode is a failure mode detection. The
controller may communicate the failure mode detection facility,
such as where the detection mode is a power mode detection and the
alarm state is indicative of a power related limitation data of the
anticipated state information, the detection mode is a performance
mode detection and the alarm state is indicative of a
high-performance limitation data of the anticipated state
information, and the like. The analysis circuit may set the alarm
state when the alarm threshold level is exceeded for an alternate
input channel in the first group of input channels, such as where
the setting of the alarm state for the first input channel and the
alternate input channel are determined to be a multiple-instance
anomaly detection, wherein the alternate routing of input channels
comprises the first input channel and a second input channel,
wherein the sensor data from the first input channel and the second
input channel contribute to simultaneous data analysis. The
alternate routing of input channels may include a change in a
routing collection parameter, such as for an increase in sampling
rate, an increase in the number of channels being sampled, a burst
sampling of at least one of the plurality of input channels, and
the like.
[1000] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels for the plurality of input channels; providing a
data storage structured to store sensor specifications for sensors
that correspond to the input channels; providing a data analysis
circuit structured to evaluate the sensor data with respect to
stored anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channels; and providing a response circuit structured to
change the routing of the input channels for data collection from
the first routing of input channels to an alternate routing of
input channels, wherein the alternate routing of input channels
comprise the first input channel and a group of input channels
related to the first input channel. In embodiments, the system may
be deployed locally on the data collector, deployed in part locally
on the data collector and in part on a remote information
technology infrastructure component apart from the collector,
wherein each of the input channels correspond to a sensor located
in the environment.
[1001] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions may
comprise: providing a data collector communicatively coupled to a
plurality of input channels; providing a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
the input channels, wherein the data acquisition circuit acquires
sensor data from a first route of input channels for the plurality
of input channels; providing a data storage structured to store
sensor specifications for sensors that correspond to the input
channels; providing a data analysis circuit structured to evaluate
the sensor data with respect to stored anticipated state
information, wherein the anticipated state information comprises an
alarm threshold level, and wherein the data analysis circuit sets
an alarm state when the alarm threshold level is exceeded for a
first input channel in the first group of input channels; and
providing a response circuit structured to change the routing of
the input channels for data collection from the first routing of
input channels to an alternate routing of input channels, wherein
the alternate routing of input channels comprise the first input
channel and a group of input channels related to the first input
channel. In embodiments, the instructions may be deployed locally
on the data collector, deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, wherein each of
the input channels correspond to a sensor located in the
environment.
[1002] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collector
communicatively coupled to a plurality of input channels; a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels for the plurality of input channels; a data storage
structured to store sensor specifications for sensors that
correspond to the input channels; a data analysis circuit
structured to evaluate the sensor data with respect to stored
anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channels and transmits the alarm state across a network to a
routing control facility; and a response circuit structured to
change the routing of the input channels for data collection from
the first routing of input channels to an alternate routing of
input channels upon reception of a routing change indication from
the routing control facility, wherein the alternate routing of
input channels comprise the first input channel and a group of
input channels related to the first input channel, wherein the data
collector automatically executes the change in routing of the input
channels if a communication parameter of the network between the
data collector and the routing control facility is not met. In
embodiments, the instructions may be deployed locally on the data
collector, deployed in part locally on the data collector and in
part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment. The
communication parameter may be a time-period parameter within which
the routing control facility must respond. The communication
parameter may be a network availability parameter, such as a
network connection parameter or bandwidth requirement. The group of
input channels related to the first input channel may be at least
in part taken from the plurality of input channels not included in
the first routing of input channels. The alarm state may indicate a
detection mode, such as an operational mode detection comprising an
out-of-range detection, a maintenance mode detection comprising an
alarm detected during maintenance, and the like. The detection mode
may be a failure mode detection, such as when the controller
communicates the failure mode detection facility, the alarm state
is indicative of a power related limitation data of the anticipated
state information, the detection mode is a performance mode
detection where the alarm state is indicative of a high-performance
limitation data of the anticipated state information, and the like.
The analysis circuit may set the alarm state when the alarm
threshold level is exceeded for an alternate input channel in the
first group of input channels, such as where the setting of the
alarm state for the first input channel and the alternate input
channel are determined to be a multiple-instance anomaly detection,
wherein the alternate routing of input channels comprises the first
input channel and a second input channel, wherein the sensor data
from the first input channel and the second input channel
contribute to simultaneous data analysis. The alternate routing of
input channels may be a change in a routing collection parameter,
such as an increase in sampling rate, is an increase in the number
of channels being sampled, a burst sampling of at least one of the
plurality of input channels, and the like.
[1003] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels for the plurality of input channels; providing a
data storage structured to store sensor specifications for sensors
that correspond to the input channels; providing a data analysis
circuit structured to evaluate the sensor data with respect to
stored anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channels and transmits the alarm state across a network to a
routing control facility; and providing a response circuit
structured to change the routing of the input channels for data
collection from the first routing of input channels to an alternate
routing of input channels upon reception of a routing change
indication from the routing control facility, wherein the alternate
routing of input channels comprise the first input channel and a
group of input channels related to the first input channel, wherein
the data collector automatically executes the change in routing of
the input channels if a communication parameter of the network
between the data collector and the routing control facility is not
met. In embodiments, the instructions may be deployed locally on
the data collector, deployed in part locally on the data collector
and in part on a remote information technology infrastructure
component apart from the collector, wherein each of the input
channels correspond to a sensor located in the environment.
[1004] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a data collector communicatively coupled to a
plurality of input channels; providing a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
the input channels, wherein the data acquisition circuit acquires
sensor data from a first route of input channels for the plurality
of input channels; providing a data storage structured to store
sensor specifications for sensors that correspond to the input
channels; providing a data analysis circuit structured to evaluate
the sensor data with respect to stored anticipated state
information, wherein the anticipated state information comprises an
alarm threshold level, and wherein the data analysis circuit sets
an alarm state when the alarm threshold level is exceeded for a
first input channel in the first group of input channels and
transmits the alarm state across a network to a routing control
facility; and providing a response circuit structured to change the
routing of the input channels for data collection from the first
routing of input channels to an alternate routing of input channels
upon reception of a routing change indication from the routing
control facility, wherein the alternate routing of input channels
comprise the first input channel and a group of input channels
related to the first input channel, wherein the data collector
automatically executes the change in routing of the input channels
if a communication parameter of the network between the data
collector and the routing control facility is not met. In
embodiments, the instructions may be deployed locally on the data
collector, deployed in part locally on the data collector and in
part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment.
[1005] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a first and second data
collector communicatively coupled to a plurality of input channels;
a data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels for the plurality of input channels; a data storage
structured to store sensor specifications for sensors that
correspond to the input channels; a data analysis circuit
structured to evaluate the sensor data with respect to stored
anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channels; a communication circuit structured to communicate
with a second data collector, wherein the second data collector
transmits a state message related to a first input channel from the
first route of input channels; and a response circuit structured to
change the routing of the input channels for data collection from
the first routing of input channels to an alternate routing of
input channels based on the state message from the second data
collector, wherein the alternate routing of input channel comprise
the first input channel and a group of input channels related to
the first input sensor. In embodiments, the system may be deployed
locally on the data collector, deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, wherein each of
the input channels correspond to a sensor located in the
environment. The set state message transmitted from the second data
collector may be from a second input channel that is mounted in
proximity to the first input channel. The set alarm transmitted
from the second controller may be from a second input sensor that
is part of a related group of input sensors comprising the first
input sensor. The group of input channels related to the first
input channel may be at least in part taken from the plurality of
input channels not included in the first routing of input channels.
The alarm state may indicate a detection mode, such as where the
detection mode is an operational mode detection comprising an
out-of-range detection, a maintenance mode detection comprising an
alarm detected during maintenance, is a failure mode detection, and
the like. The controller may communicate the failure mode detection
facility, such as where the detection mode is a power mode
detection and the alarm state is indicative of a power related
limitation data of the anticipated state information, the detection
mode is a performance mode detection where the alarm state is
indicative of a high-performance limitation data of the anticipated
state information, and the like. The analysis circuit may set the
alarm state when the alarm threshold level is exceeded for an
alternate input channel in the first group of input channels, such
as where the setting of the alarm state for the first input channel
and the alternate input channel are determined to be a
multiple-instance anomaly detection, wherein the alternate routing
of input channels comprises the first input channel and a second
input channel, wherein the sensor data from the first input channel
and the second input channel contribute to simultaneous data
analysis. The alternate routing of input channels may be a change
in a routing collection parameter, such as an increase in sampling
rate, an increase in the number of channels being sampled, a burst
sampling of at least one of the plurality of input channels, and
the like.
[1006] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a first and second
data collector communicatively coupled to a plurality of input
channels; providing a data acquisition circuit structured to
interpret a plurality of detection values, each of the plurality of
detection values corresponding to at least one of the input
channels, wherein the data acquisition circuit acquires sensor data
from a first route of input channels for the plurality of input
channels; providing a data storage structured to store sensor
specifications for sensors that correspond to the input channels;
providing a data analysis circuit structured to evaluate the sensor
data with respect to stored anticipated state information, wherein
the anticipated state information comprises an alarm threshold
level, and wherein the data analysis circuit sets an alarm state
when the alarm threshold level is exceeded for a first input
channel in the first group of input channels; providing a
communication circuit structured to communicate with a second data
collector, wherein the second data collector transmits a state
message related to a first input channel from the first route of
input channels, and providing a response circuit structured to
change the routing of the input channels for data collection from
the first routing of input channels to an alternate routing of
input channels based on the state message from the second data
collector, wherein the alternate routing of input channel comprise
the first input channel and a group of input channels related to
the first input sensor. In embodiments, the method may be deployed
locally on the data collector, deployed in part locally on the data
collector and in part on a remote information technology
infrastructure component apart from the collector, wherein each of
the input channels correspond to a sensor located in the
environment.
[1007] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a first and second data collector
communicatively coupled to a plurality of input channels; providing
a data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels for the plurality of input channels; providing a
data storage structured to store sensor specifications for sensors
that correspond to the input channels; providing a data analysis
circuit structured to evaluate the sensor data with respect to
stored anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channels; providing a communication circuit structured to
communicate with a second data collector, wherein the second data
collector transmits a state message related to a first input
channel from the first route of input channels, and providing a
response circuit structured to change the routing of the input
channels for data collection from the first routing of input
channels to an alternate routing of input channels based on the
state message from the second data collector, wherein the alternate
routing of input channel comprise the first input channel and a
group of input channels related to the first input sensor. In
embodiments, the instructions may be deployed locally on the data
collector, deployed in part locally on the data collector and in
part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment.
[1008] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collector
communicatively coupled to a plurality of input channels; a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channel, wherein the
data acquisition circuit acquires sensor data from a first group of
input channels from the plurality of input channels; a data storage
structured to store sensor specifications for sensors that
correspond to the input channels; a data analysis circuit
structured to evaluate the sensor data with respect to stored
anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channel; and a response circuit structured to change the
input channels being collected from the first group of input
channels to an alternative group of input channels, wherein the
alternate group of input channels comprise the first input channel
and a group of input channels related to the first input sensor. In
embodiments, the system may be deployed locally on the data
collector, deployed in part locally on the data collector and in
part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment. The group of
input sensors related to the first input sensor may be at least in
part taken from the plurality of input sensors not included in the
first group of input sensors. The first group of input channels
related to the first input channel may be at least in part taken
from the plurality of input channels not included in the first
routing of input channels. The alarm state may indicate a detection
mode, such as where the detection mode is an operational mode
detection comprising an out-of-range detection, a maintenance mode
detection comprising an alarm detected during maintenance. The
detection mode may be a failure mode detection, such as where the
controller communicates the failure mode detection facility. The
detection mode may be a power mode detection where the alarm state
is indicative of a power related limitation data of the anticipated
state information. The detection mode may be a performance mode
detection, where the alarm state is indicative of a
high-performance limitation data of the anticipated state
information. The analysis circuit may set the alarm state when the
alarm threshold level is exceeded for an alternate input channel in
the first group of input channels, such as when the setting of the
alarm state for the first input channel and the alternate input
channel are determined to be a multiple-instance anomaly detection,
wherein the alternate routing of input channels comprises the first
input channel and a second input channel, wherein the sensor data
from the first input channel and the second input channel
contribute to simultaneous data analysis. An alternative group of
input channels may include a change in a routing collection
parameter, such as where the routing collection parameter is an
increase in sampling rate, an increase in the number of channels
being sampled, a burst sampling of at least one of the plurality of
input channels, and the like.
[1009] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channel, wherein the
data acquisition circuit acquires sensor data from a first group of
input channels from the plurality of input channels; providing a
data storage structured to store sensor specifications for sensors
that correspond to the input channels; providing a data analysis
circuit structured to evaluate the sensor data with respect to
stored anticipated state information, wherein the anticipated state
information comprises an alarm threshold level, and wherein the
data analysis circuit sets an alarm state when the alarm threshold
level is exceeded for a first input channel in the first group of
input channel; and providing a response circuit structured to
change the input channels being collected from the first group of
input channels to an alternative group of input channels, wherein
the alternate group of input channels comprise the first input
channel and a group of input channels related to the first input
sensor. In embodiments, the method may be deployed locally on the
data collector, deployed in part locally on the data collector and
in part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment.
[1010] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a data collector communicatively coupled to a
plurality of input channels; providing a data acquisition circuit
structured to interpret a plurality of detection values, each of
the plurality of detection values corresponding to at least one of
the input channel, wherein the data acquisition circuit acquires
sensor data from a first group of input channels from the plurality
of input channels; providing a data storage structured to store
sensor specifications for sensors that correspond to the input
channels; providing a data analysis circuit structured to evaluate
the sensor data with respect to stored anticipated state
information, wherein the anticipated state information comprises an
alarm threshold level, and wherein the data analysis circuit sets
an alarm state when the alarm threshold level is exceeded for a
first input channel in the first group of input channel; and
providing a response circuit structured to change the input
channels being collected from the first group of input channels to
an alternative group of input channels, wherein the alternate group
of input channels comprise the first input channel and a group of
input channels related to the first input sensor. In embodiments,
the instructions may be deployed locally on the data collector,
deployed in part locally on the data collector and in part on a
remote information technology infrastructure component apart from
the collector, wherein each of the input channels correspond to a
sensor located in the environment.
[1011] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collector
communicatively coupled to a plurality of input channels; a data
storage structured to store a plurality of collector route
templates, sensor specifications for sensors that correspond to the
input channels, wherein the plurality of collector route templates
each comprise a different sensor collection routine; a data
acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels; and a data analysis circuit structured to evaluate
the sensor data with respect to stored anticipated state
information, wherein the anticipated state information comprises an
alarm threshold level, and wherein the data analysis circuit sets
an alarm state when the alarm threshold level is exceeded for a
first input channel in the first group of input channels, wherein
the data collector is configured to switch from a current routing
template collection routine to an alternate routing template
collection routine based on a setting of an alarm state. In
embodiments, the system may be deployed locally on the data
collector, deployed in part locally on the data collector and in
part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment. The setting of
the alarm state may be based on operational mode routing collection
schemes, such as where the operational mode is at least one of a
normal operational mode, a peak operational mode, an idle
operational mode, a maintenance operational mode, and a power
saving operational mode. The alarm threshold level may be
associated with a sensed change to one of the plurality of input
channels, such as where the sensed change is a failure condition,
is a performance condition, a power condition, a temperature
condition, a vibration condition, and the like. The alarm state may
indicate a detection mode, such as where the detection mode is an
operational mode detection comprising an out-of-range detection, a
maintenance mode detection comprising an alarm detected during
maintenance, and the like. The detection mode may be a power mode
detection, where the alarm state is indicative of a power related
limitation data of the anticipated state information. The detection
mode may be a performance mode detection, where the alarm state is
indicative of a high-performance limitation data of the anticipated
state information. The analysis circuit may set the alarm state
when the alarm threshold level is exceeded for an alternate input
channel, such as wherein the setting of the alarm state is
determined to be a multiple-instance anomaly detection. The
alternate routing template may be a change to an input channel
routing collection parameter. The routing collection parameter may
be an increase in sampling rate, such as an increase in the number
of channels being sampled, a burst sampling of at least one of the
plurality of input channels, and the like.
[1012] In embodiments, a computer-implemented method for
implementing a monitoring system for data collection in an
industrial environment may comprise: providing a data collector
communicatively coupled to a plurality of input channels; providing
a data storage structured to store a plurality of collector route
templates, sensor specifications for sensors that correspond to the
input channels, wherein the plurality of collector route templates
each comprise a different sensor collection routine; providing a
data acquisition circuit structured to interpret a plurality of
detection values, each of the plurality of detection values
corresponding to at least one of the input channels, wherein the
data acquisition circuit acquires sensor data from a first route of
input channels; and providing a data analysis circuit structured to
evaluate the sensor data with respect to stored anticipated state
information, wherein the anticipated state information comprises an
alarm threshold level, and wherein the data analysis circuit sets
an alarm state when the alarm threshold level is exceeded for a
first input channel in the first group of input channels, wherein
the data collector is configured to switch from a current routing
template collection routine to an alternate routing template
collection routine based on a setting of an alarm state. In
embodiments, the system may be deployed locally on the data
collector, deployed in part locally on the data collector and in
part on a remote information technology infrastructure component
apart from the collector, wherein each of the input channels
correspond to a sensor located in the environment.
[1013] In embodiments, one or more non-transitory computer-readable
media comprising computer executable instructions that, when
executed, may cause at least one processor to perform actions
comprising: providing a data collector communicatively coupled to a
plurality of input channels; providing a data storage structured to
store a plurality of collector route templates, sensor
specifications for sensors that correspond to the input channels,
wherein the plurality of collector route templates each comprise a
different sensor collection routine; providing a data acquisition
circuit structured to interpret a plurality of detection values,
each of the plurality of detection values corresponding to at least
one of the input channels, wherein the data acquisition circuit
acquires sensor data from a first route of input channels; and
providing a data analysis circuit structured to evaluate the sensor
data with respect to stored anticipated state information, wherein
the anticipated state information comprises an alarm threshold
level, and wherein the data analysis circuit sets an alarm state
when the alarm threshold level is exceeded for a first input
channel in the first group of input channels, wherein the data
collector is configured to switch from a current routing template
collection routine to an alternate routing template collection
routine based on a setting of an alarm state. In embodiments, the
instructions may be deployed locally on the data collector,
deployed in part locally on the data collector and in part on a
remote information technology infrastructure component apart from
the collector, wherein each of the input channels correspond to a
sensor located in the environment.
[1014] Methods and systems are disclosed herein for a system for
data collection in an industrial environment using intelligent
management of data collection bands, referred to herein in some
cases as smart bands. Smart bands may facilitate intelligent,
situational, context-aware collection of data, such as by a data
collector (such as any of the wide range of data collector
embodiments described throughout this disclosure). Intelligent
management of data collection via smart bands may improve various
parameters of data collection, as well as parameters of the
processes, applications, and products that depend on data
collection, such as data quality parameters, consistency
parameters, efficiency parameters, comprehensiveness parameters,
reliability parameters, effectiveness parameters, storage
utilization parameters, yield parameters (including financial
yield, output yield, and reduction of adverse events), energy
consumption parameters, bandwidth utilization parameters,
input/output speed parameters, redundancy parameters, security
parameters, safety parameters, interference parameters,
signal-to-noise parameters, statistical relevancy parameters, and
others. Intelligent management of smart bands may optimize across
one or more such parameters, such as based on a weighting of the
value of the parameters; for example, a smart band may be managed
to provide a given level of redundancy for critical data, while not
exceeding a specified level of energy usage. This may include using
a variety of optimization techniques described throughout this
disclosure and the documents incorporated herein by reference.
[1015] In embodiments, such methods and systems for intelligent
management of smart bands include an expert system and supporting
technology components, services, processes, modules, applications
and interfaces, for managing the smart bands (collectively referred
to in some cases as a smart band platform 10722), which may include
a model-based expert system, a rule-based expert system, an expert
system using artificial intelligence (such as a machine learning
system, which may include a neural net expert system, a
self-organizing map system, a human-supervised machine learning
system, a state determination system, a classification system, or
other artificial intelligence system), or various hybrids or
combinations of any of the above. References to an expert system
should be understood to encompass utilization of any one of the
foregoing or suitable combinations, except where context indicates
otherwise. Intelligent management may be of data collection of
various types of data (e.g., vibration data, noise data and other
sensor data of the types described throughout this disclosure) for
event detection, state detection, and the like. Intelligent
management may include managing a plurality of smart bands each
directed at supporting an identified application, process or
workflow, such as confirming progress toward or alignment with one
or more objectives, goals, rules, policies, or guidelines.
Intelligent management may also involve managing data collection
bands targeted to backing out an unknown variable based on
collection of other data (such as based on a model of the behavior
of a system that involves the variable), selecting preferred inputs
among available inputs (including specifying combinations, fusions,
or multiplexing of inputs), and/or specifying an input band among
available input bands.
[1016] Data collection bands, or smart bands, may include any
number of items such as sensors, input channels, data locations,
data streams, data protocols, data extraction techniques, data
transformation techniques, data loading techniques, data types,
frequency of sampling, placement of sensors, static data points,
metadata, fusion of data, multiplexing of data, and the like as
described herein. Smart band settings, which may be used
interchangeably with smart band and data collection band, may
describe the configuration and makeup of the smart band, such as by
specifying the parameters that define the smart band. For example,
data collection bands, or smart bands, may include one or more
frequencies to measure. Frequency data may further include at least
one of a group of spectral peaks, a true-peak level, a crest factor
derived from a time waveform, and an overall waveform derived from
a vibration envelope, as well as other signal characteristics
described throughout this disclosure. Smart bands may include
sensors measuring or data regarding one or more wavelengths, one or
more spectra, and/or one or more types of data from various sensors
and metadata. Smart bands may include one or more sensors or types
of sensors of a wide range of types, such as described throughout
this disclosure and the documents incorporated by reference herein.
Indeed, the sensors described herein may be used in any of the
methods or systems described throughout this disclosure. For
example, one sensor may be an accelerometer, such as one that
measures voltage per G ("V/G") of acceleration (e.g., 100 mV/G, 500
mV/G, 1 V/G, 5 V/G, 10 V/G, and the like). In embodiments, the data
collection band circuit may alter the makeup of the subset of the
plurality of sensors used in a smart band based on optimizing the
responsiveness of the sensor, such as for example choosing an
accelerometer better suited for measuring acceleration of a low
speed mixer versus one better suited for measuring acceleration of
a high speed industrial centrifuge. Choosing may be done
intelligently, such as for example with a proximity probe and
multiple accelerometers disposed on a centrifuge where while at low
speed, one accelerometer is used for measuring in the smart band
and another is used at high speeds. Accelerometers come in various
types, such as piezo-electric crystal, low frequency (e.g., 10
V/G), high speed compressors (10 MV/G), MEMS, and the like. In
another example, one sensor may be a proximity probe which can be
used for sleeve or tilt-pad bearings (e.g., oil bath), or a
velocity probe. In yet another example, one sensor may be a
solid-state relay (SSR) that is structured to automatically
interface with a routed data collector (such as a mobile or
portable data collector) to obtain or deliver data. In another
example, a mobile or portable data collector may be routed to alter
the makeup of the plurality of available sensors, such as by
bringing an appropriate accelerometer to a point of sensing, such
as on or near a component of a machine. In still another example,
one sensor may be a triax probe (e.g., a 100 MV/G triax probe),
that in embodiments is used for portable data collection. In some
embodiments, of a triax probe, a vertical element on one axis of
the probe may have a high frequency response while the ones mounted
horizontally may influence the frequency response of the whole
triax. In another example, one sensor may be a temperature sensor
and may include a probe with a temperature sensor built inside,
such as to obtain a bearing temperature. In still additional
examples, sensors may be ultrasonic, microphone, touch, capacitive,
vibration, acoustic, pressure, strain gauges, thermographic (e.g.,
camera), imaging (e.g., camera, laser, IR, structured light), a
field detector, an EMF meter to measure an AC electromagnetic
field, a gaussmeter, a motion detector, a chemical detector, a gas
detector, a CBRNE detector, a vibration transducer, a magnetometer,
positional, location-based, a velocity sensor, a displacement
sensor, a tachometer, a flow sensor, a level sensor, a proximity
sensor, a pH sensor, a hygrometer/moisture sensor, a densitometric
sensor, an anemometer, a viscometer, or any analog industrial
sensor and/or digital industrial sensor. In a further example,
sensors may be directed at detecting or measuring ambient noise,
such as a sound sensor or microphone, an ultrasound sensor, an
acoustic wave sensor, and an optical vibration sensor (e.g., using
a camera to see oscillations that produce noise). In still another
example, one sensor may be a motion detector.
[1017] Data collection bands, or smart bands, may be of or may be
configured to encompass one or more frequencies, wavelengths, or
spectra for particular sensors, for particular groups of sensors,
or for combined signals from multiple sensors (such as involving
multiplexing or sensor fusion).
[1018] Data collection bands, or smart bands, may be of or may be
configured to encompass one or more sensors or sensor data
(including groups of sensors and combined signals) from one or more
pieces of equipment/components, areas of an installation, disparate
but interconnected areas of an installation (e.g., a machine
assembly line and a boiler room used to power the line), or
locations (e.g., a building in Cambridge and a building in Boston).
Smart band settings, configurations, instructions, or
specifications (collectively referred to herein using any one of
those terms) may include where to place a sensor, how frequently to
sample a data point or points, the granularity at which a sample is
taken (e.g., a number of sampling points per fraction of a second),
which sensor of a set of redundant sensors to sample, an average
sampling protocol for redundant sensors, and any other aspect that
would affect data acquisition.
[1019] Within the smart band platform 10722, an expert system,
which may comprise a neural net, a model-based system, a rule-based
system, a machine learning data analysis circuit, and/or a hybrid
of any of those, may begin iteration towards convergence on a smart
band that is optimized for a particular goal or outcome, such as
predicting and managing performance, health, or other
characteristics of a piece of equipment, a component, or a system
of equipment or components. Based on continuous or periodic
analysis of sensor data, as patterns/trends are identified, or
outliers appear, or a group of sensor readings begin to change,
etc., the expert system may modify its data collection bands
intelligently. This may occur by triggering a rule that reflects a
model or understanding of system behavior (e.g., recognizing a
shift in operating mode that calls for different sensors as
velocity of a shaft increases) or it may occur under control of a
neural net (either in combination with a rule-based approach or on
its own), where inputs are provided such that the neural net over
time learns to select appropriate collection modes based on
feedback as to successful outcomes (e.g., successful classification
of the state of a system, successful prediction, successful
operation relative to a metric, or the like). For example, when a
new pressure reactor is installed in a chemical processing
facility, data from the current data collection band may not
accurately predict the state or metric of operation of the system,
thus, the machine learning data analysis circuit may begin to
iterate to determine if a new data collection band is better at
predicting a state. Based on offset system data, such as from a
library or other data structure, certain sensors, frequency bands
or other smart band members may be used in the smart band initially
and data may be collected to assess performance. As the neural net
iterates, other sensors/frequency bands may be accessed to
determine their relative weight in identifying performance metrics.
Over time, a new frequency band may be identified (or a new
collection of sensors, a new set of configurations for sensors, or
the like) as a better gauge of performance in the system and the
expert system may modify its data collection band based on this
iteration. For example, perhaps a slightly different or older
associated turbine agitator in a chemical reaction facility dampens
one or more vibration frequencies while a different frequency is of
higher amplitude and present during optimal performance than what
was seen in the offset system. In this example, the smart band may
be altered from what was suggested by the corresponding offset
system to capture the higher amplitude frequency that is present in
the current system.
[1020] The expert system, in embodiments involving a neural net or
other machine learning system, may be seeded and may iterate, such
as towards convergence on a smart band, based on feedback and
operation parameters, such as described herein. Certain feedback
may include utilization measures, efficiency measures (e.g., power
or energy utilization, use of storage, use of bandwidth, use of
input/output use of perishable materials, use of fuel, and/or
financial efficiency), measures of success in prediction or
anticipation of states (e.g., avoidance and mitigation of faults),
productivity measures (e.g., workflow), yield measures, and profit
measures. Certain parameters may include: storage parameters (e.g.,
data storage, fuel storage, storage of inventory and the like);
network parameters (e.g., network bandwidth, input/output speeds,
network utilization, network cost, network speed, network
availability and the like); transmission parameters (e.g., quality
of transmission of data, speed of transmission of data, error rates
in transmission, cost of transmission and the like); security
parameters (e.g., number and/or type of exposure events;
vulnerability to attack, data loss, data breach, access parameters,
and the like); location and positioning parameters (e.g., location
of data collectors, location of workers, location of machines and
equipment, location of inventory units, location of parts and
materials, location of network access points, location of ingress
and egress points, location of landing positions, location of
sensor sets, location of network infrastructure, location of power
sources and the like); input selection parameters, data combination
parameters (e.g., for multiplexing, extraction, transformation,
loading, and the like); power parameters; states (e.g., operating
modes, availability states, environmental states, fault modes,
maintenance modes, anticipated states); events; and equipment
specifications. With respect to states, operating modes may include
mobility modes (direction, speed, acceleration, and the like), type
of mobility modes (e.g., rolling, flying, sliding, levitation,
hovering, floating, and the like), performance modes (e.g., gears,
rotational speeds, heat levels, assembly line speeds, voltage
levels, frequency levels, and the like), output modes, fuel
conversion modes, resource consumption modes, and financial
performance modes (e.g., yield, profitability, and the like).
Availability states may refer to anticipating conditions that could
cause machine to go offline or require backup. Environmental states
may refer to ambient temperature, ambient humidity/moisture,
ambient pressure, ambient wind/fluid flow, presence of pollution or
contaminants, presence of interfering elements (e.g., electrical
noise, vibration), power availability, and power quality.
Anticipated states may include: achieving or not achieving a
desired goal, such as a specified/threshold output production rate,
a specified/threshold generation rate, an operational
efficiency/failure rate, a financial efficiency/profit goal, a
power efficiency/resource utilization; an avoidance of a fault
condition (e.g., overheating, slow performance, excessive speed,
excessive motion, excessive vibration/oscillation, excessive
acceleration, expansion/contraction, electrical failure, running
out of stored power/fuel, overpressure, excessive radiation/melt
down, fire, freezing, failure of fluid flow (e.g., stuck valves,
frozen fluids); mechanical failures (e.g., broken component, worn
component, faulty coupling, misalignment, asymmetries/deflection,
damaged component (e.g., deflection, strain, stress, cracking],
imbalances, collisions, jammed elements, and lost or slipping chain
or belt); avoidance of a dangerous condition or catastrophic
failure; and availability (online status).
[1021] The expert system may comprise or be seeded with a model
that predicts an outcome or state given a set of data (which may
comprise inputs from sensors, such as via a data collector, as well
as other data, such as from system components, from external
systems and from external data sources). For example, the model may
be an operating model for an industrial environment, machine, or
workflow. In another example, the model may be for anticipating
states, for predicting fault and optimizing maintenance, for
self-organizing storage (e.g., on devices, in data pools and/or in
the cloud), for optimizing data transport (such as for optimizing
network coding, network-condition-sensitive routing, and the like),
for optimizing data marketplaces, and the like.
[1022] The iteration of the expert system may result in any number
of downstream actions based on analysis of data from the smart
band. In an embodiment, the expert system may determine that the
system should either keep or modify operational parameters,
equipment or a weighting of a neural net model given a desired
goal, such as a specified/threshold output production rate,
specified/threshold generation rate, an operational
efficiency/failure rate, a financial efficiency/profit goal, a
power efficiency/resource utilization, an avoidance of a fault
condition, an avoidance of a dangerous condition or catastrophic
failure, and the like. In embodiments, the adjustments may be based
on determining context of an industrial system, such as
understanding a type of equipment, its purpose, its typical
operating modes, the functional specifications for the equipment,
the relationship of the equipment to other features of the
environment (including any other systems that provide input to or
take input from the equipment), the presence and role of operators
(including humans and automated control systems), and ambient or
environmental conditions. For example, in order to achieve a profit
goal, a pipeline in a refinery may need to operate for a certain
amount of time a day and/or at a certain flow rate. The expert
system may be seeded with a model for operation of the pipeline in
a manner that results in a specified profit goal, such as
indicating a given flow rate of material through the pipeline based
on the current market sale price for the material and the cost of
getting the material into the pipeline. As it acquires data and
iterates, the model will predict whether the profit goal will be
achieved given the current data. Based on the results of the
iteration of the expert system, a recommendation may be made (or a
control instruction may be automatically provided) to operate the
pipeline at a higher flow rate, to keep it operational for longer
or the like. Further, as the system iterates, one or more
additional sensors may be sampled in the model to determine if
their addition to the smart band would improve predicting a state.
In another embodiment, the expert system may determine that the
system should either keep or modify operational parameters,
equipment or a weighting of a neural net or other model given a
constraint of operation (e.g., meeting a required endpoint (e.g.,
delivery date, amount, cost, coordination with another system),
operating with a limited resource (e.g., power, fuel, battery),
storage (e.g., data storage), bandwidth (e.g., local network, p2p,
WAN, internet bandwidth, availability, or input/output capacity),
authorization (e.g., role-based)), a warranty limitation, a
manufacturer's guideline, a maintenance guideline). For example, a
constraint of operating a boiler in a refinery is that the aeration
of the boiler feedwater needs to be reduced in the cycle;
therefore, the boiler must coordinate with the deaerator. In this
example, the expert system is seeded with a model for operation of
the boiler in coordination with the de-aerator that results in a
specified overall performance. As sensor data from the system is
acquired, the expert system may determine that an aspect of one or
both of the boiler and aerator must be changed to continue to
achieve the specific overall performance. In a further embodiment,
the expert system may determine that the system should either keep
or modify operational parameters, equipment or a weighting of a
neural net model given an identified choke point. In still another
embodiment, the expert system may determine that the system should
either keep or modify operational parameters, equipment or a
weighting of a neural net model given an off-nominal operation. For
example, a reciprocating compressor in a refinery that delivers
gases at high pressure may be measured as having an off-nominal
operation by sensors that feed their data into an expert system
(optionally including a neural net or other machine learning
system). As the expert system iterates and receives the off-nominal
data, it may predict that the refinery will not achieve a specified
goal and will recommend an action, such as taking the reciprocating
compressor offline for maintenance. In another embodiment, the
expert system may determine that the system should collect
more/fewer data points from one or more sensors. For example, an
anchor agitator in a pharmaceutical processing plant may be
programmed to agitate the contents of a tank until a certain level
of viscosity (e.g., as measured in centipoise) is obtained. As the
expert system collects data throughout the run indicating an
increase in viscosity, the expert system may recommend collecting
additional data points to confirm a predicted state in the face of
the increased strain on the plant systems from the viscosity. In
yet another embodiment, the expert system may determine that the
system should change a data storage technique. In still another
example, the expert system may determine that the system should
change a data presentation mode or manner. In a further embodiment,
the expert system may determine that the system should apply one or
more filters (low pass, high pass, band pass, etc.) to collected
data. In yet a further embodiment, the expert system may determine
that the system should collect data from a new smart band/new set
of sensors and/or begin measuring a new aspect that the neural net
identified itself. For example, various measurements may be made of
paddle-type agitator mixers operating in a pharmaceutical plant,
such as mixing times, temperature, homogeneous substrate
distribution, heat exchange with internal structures and the tank
wall or oxygen transfer rate, mechanical stress, forces and torques
on agitator vessels and internal structures, and the like. Various
sensor data streams may be included in a smart band monitoring
these various aspects of the paddle-type agitator mixer, such as a
flow meter, a thermometer, and others. As the expert system
iterates, perhaps having been seeded with minimal data from during
the agitator's run, a new aspect of the operation may become
apparent, such as the impact of pH on the state of the run. Thus, a
new smart band will be identified by the expert system that
includes sensor data from a pH meter. In yet still a further
embodiment, the expert system may determine that the system should
discontinue collection of data from a smart band, one or more
sensors, or the like. In another embodiment, the expert system may
determine that the system should initiate data collection from a
new smart band, such as a new smart band identified by the neural
net itself. In yet another embodiment, the expert system may
determine that the system should adjust the weights/biases of a
model used by the expert system. In still another embodiment, the
expert system may determine that the system should remove/re-task
under-utilized equipment. For example, a plurality of agitators
working with a pump blasting liquid in a pharmaceutical processing
plant may be monitored during operation of the plant by the expert
system. Through iteration of the expert system seeded with data
from a run of the plant with the agitators, the expert system may
predict that a state will be achieved even if one or more agitators
are taken out of service.
[1023] In embodiments, a monitoring system for data collection in
an industrial environment may include a plurality of input sensors,
such as any of those described herein, communicatively coupled to a
data collector having a controller. The monitoring system may
include a data collection band circuit structured to determine at
least one subset of the plurality of sensors from which to process
output data. The monitoring system may also include a machine
learning data analysis circuit structured to receive output data
from the at least one subset of the plurality of sensors and learn
received output data patterns indicative of a state. In some
embodiments, the data collection band circuit may alter the at
least one subset of the plurality of sensors, or an aspect thereof,
based on one or more of the learned received output data patterns
and the state. In certain embodiments, the machine learning data
analysis circuit is seeded with a model that enables it to learn
data patterns. The model may be a physical model, an operational
model, a system model, and the like. In other embodiments, the
machine learning data analysis circuit is structured for deep
learning wherein input data is fed to the circuit with no or
minimal seeding and the machine learning data analysis circuit
learns based on output feedback. For example, a static mixer in a
chemical processing plant producing polymers may be used to
facilitate the polymerization reaction. The static mixer may employ
turbulent or laminar flow in its operation. Minimal data, such as
heat transfer, velocity of flow out of the mixer, Reynolds number
or pressure drop, acquired during the operation of the static mixer
may be fed into the expert system which may iterate towards a
prediction based on initial feedback (e.g., viscosity of the
polymer, color of the polymer, reactivity of the polymer).
[1024] There may be a balance of multiple goals/guidelines in the
management of smart bands by the expert system. For example, a
repair and maintenance organization (RMO) may have operating
parameters designed for maintenance of a storage tank in a
refinery, while the owner of the refinery may have particular
operating parameters for the storage tank that are designed for
meeting a production goal. These goals, in this example relating to
a maintenance goal or a production output, may be tracked by a
different data collection bands. For example, maintenance of a
storage tank may be tracked by sensors including a vibration
transducer and a strain gauge, while the production goal of a
storage tank may be tracked by sensors including a temperature
sensor and a flow meter. The expert system may (optionally using a
neural net, machine learning system, deep learning system, or the
like, which may occur under supervision by one or more supervisors
(human or automated)) intelligently manage bands aligned with
different goals and assign weights, parameter modifications, or
recommendations based on a factor, such as a bias towards one goal
or a compromise to allow better alignment with all goals being
tracked, for example. Compromises among the goals delivered to the
expert system may be based on one or more hierarchies or rules
(relating to the authority, role, criticality, or the like) of the
applicable goals. In embodiments, compromises among goals may be
optimized using machine learning, such as a neural net, deep
learning system, or other artificial intelligence system as
described throughout this disclosure. In one illustrative example,
in a chemical processing plant where a gas-powered agitator is
operating, the expert system may manage multiple smart bands, such
as one directed to detecting the operational status of the
gas-powered agitator, one directed at identifying a probability of
hitting a production goal, and one directed at determining if the
operation of the gas-powered agitator is meeting a fuel efficiency
goal. Each of these smart bands may be populated with different
sensors or data from different sensors (e.g., a vibration
transducer to indicate operational status, a flow meter to indicate
production goal, and a fuel gauge to indicate a fuel efficiency)
whose output data are indicative of an aspect of the particular
goal. Where a single sensor or a set of sensors is helpful for more
than one goal, overlapping smart bands (having some sensors in
common and other sensors not in common) may take input from that
sensor or set of sensors, as managed by the smart band platform
10722. If there are constraints on data collection (such as due to
power limitations, storage limitations, bandwidth limitations,
input/output processing capabilities, or the like), a rule may
indicate that one goal (e.g., a fuel utilization goal or a
pollution reduction goal that is mandated by law or regulation)
takes precedence, such that the data collection for the smart bands
associated with that goal are maintained as others are paused or
shut down. Management of prioritization of goals may be
hierarchical or may occur by machine learning. The expert system
may be seeded with models, or may not be seeded at all, in
iterating towards a predicted state (i.e., meeting the goal) given
the current data it has acquired. In this example, during operation
of the gas-powered agitator, the plant owner may decide to bias the
system towards fuel efficiency. All of the bands may still be
monitored, but as the expert system iterates and predicts that the
system will not meet or is not meeting a particular goal, and then
offers recommended changes directed at increasing the chance of
meeting the goal, the plant owner may structure the system with a
bias towards fuel efficiency so that the recommended changes to
parameters affecting fuel efficiency are made in favor of making
other recommended changes.
[1025] In embodiments, the expert system may continue iterating in
a deep-learning fashion to arrive at a single smart band, after
being seeded with more than one smart band, that optimizes meeting
more than one goal. For example, there may be multiple goals
tracked for a thermic heating system in a chemical processing or a
food processing plant, such as thermal efficiency and economic
efficiency. Thermal efficiency for the thermic heating system may
be expressed by comparing BTUs put in to the system, which can be
obtained by knowing the amount of and quality of the fuel being
used, and the BTUs out of the system, which is calculated using the
flow out of the system and the temperature differential of
materials in and out of the system. Economic efficiency of the
thermic heating system may be expressed as the ratio between costs
to run the system (including fuel, labor, materials, and services)
and energy output from the system for a period of time. Data used
to track thermal efficiency may include data from a flow meter,
quality data point(s), and a thermometer, and data used to track
economic efficiency may be an energy output from the system (e.g.,
kWh) and costs data. These data may be used in smart bands by the
expert system to predict states, however, the expert system may
iterate toward a smart band that is optimized to predict states
related to both thermal and economic efficiency. The new smart band
may include data used previously in the individual smart bands but
may also use new data from different sensors or data sources. In
embodiments, the expert system may be seeded with a plurality of
smart bands and iterate to predict various states, but may also
iterate towards reducing the number of smart bands needed to
predict the same set of states.
[1026] Iteration of the expert system may be governed by rules, in
some embodiments. For example, the expert system may be structured
to collect data for seeding at a pre-determined frequency. The
expert system may be structured to iterate at least a number of
times, such as when a new component/equipment/fuel source is added,
when a sensor goes off-line, or as standard practice. For example,
when a sensor measuring the rotation of a stirrer in a food
processing line goes off-line and the expert system begins
acquiring data from a new sensor measuring the same data points,
the expert system may be structured to iterate for a number of
times before the state is utilized in or allowed to affect any
downstream actions. The expert system may be structured to train
off-line or train in situ/online. The expert system may be
structured to include static and/or manually input data in its
smart bands. For example, an expert system managing smart bands
associated with a mixer in a food processing plant may be
structured to iterate towards predicting a duration of mixing
before the food being processed achieves a particular viscosity,
wherein the smart band includes data regarding the speed of the
mixer, temperature of its contents, viscometric measurements and
the required endpoint for viscosity and temperature of the food.
The expert system may be structured to include a minimum/maximum
number of variables.
[1027] In embodiments, the expert system may be overruled. In
embodiments, the expert system may revert to prior band settings,
such as in the event the expert system fails, such as if a neural
network fails in a neural net expert system, if uncertainty is too
high in a model-based system, if the system is unable to resolve
conflicting rules in rule-based system, or the system cannot
converge on a solution in any of the foregoing. For example, sensor
data on an irrigation system used by the expert system in a smart
band may indicate a massive leak in the field, but visual
inspection, such as by a drone, indicates no such leak. In this
event, the expert system will revert to an original smart band for
seeding the expert system. In another example, one or more point
sensors on an industrial pressure cooker indicates imminent failure
in a seal, but the data collection band that the expert system
converged to with a weighting towards a performance metric did not
identify the failure. In this event, the smart band will revert to
an original setting or a version of the smart band that would have
also identified the imminent failure of the pressure cooker seal.
In embodiments, the expert system may change smart band settings in
the event that a new component is added that makes the system
closer to a different offset system. For example, a vacuum
distillation unit is added to an oil & gas refinery to distill
naphthalene, but the current smart band settings for the expert
system are derived from a refinery that distills kerosene. In this
example, a data structure with smart band settings for various
offset systems may be searched for a system that is more closely
matched to the current system. When a new offset system is
identified as more closely matched, such as one that also distill
naphthalene, the new smart band settings (e.g., which sensors to
use, where to place them, how frequently to sample, what static
data points are needed, etc. as described herein) are used to seed
the expert system to iterate towards predicting a state for the
system. In embodiments, the expert system may change smart band
settings in the event that a new set of offset data is available
from a third-party library. For example, a pharmaceutical
processing plant may have optimized a catalytic reactor to operate
in a highly efficient way and deposited the smart band settings in
a data structure. The data structure may be continuously scanned
for new smart bands that better aid in monitoring catalytic
reactions and thus, result in optimizing the operation of the
reactor.
[1028] In embodiments, the expert system may be used to uncover
unknown variables. For example, the expert system may iterate to
identify a missing variable to be used for further iterations, such
as further neural net iterations. For example, an under-utilized
tank in a legacy condensate/make-up water system of a power station
may have an unknown capacity because it is inaccessible and no
documentation exists on the tank. Various aspects of the tank may
be measured by a swarm of sensors to arrive at an estimated volume
(e.g., flow into a downstream space, duration of a dye traced
solution to work through the system), then that volume can be fed
into the neural net as a new variable in the smart band.
[1029] In embodiments, the location of expert system node locations
may be on a machine, on a data collector (or a group of them), in a
network infrastructure (enterprise or other), or in the cloud. In
embodiments, there may be distributed neurons across nodes (e.g.,
machine, data collector, network, cloud).
[1030] In an aspect, a monitoring system 10700 for data collection
in an industrial environment, comprising a plurality of input
sensors 10702 communicatively coupled to a data collector 10704
having a controller 10706, a data collection band circuit 10708
structured to determine at least one collection parameter for at
least one of the plurality of sensors 10702 from which to process
output data 10710, and a machine learning data analysis circuit
10712 structured to receive output data 10710 from the at least one
of the plurality of sensors 10702 and learn received output data
patterns 10718 indicative of a state. The data collection band
circuit 10708 alters the at least one collection parameter for the
at least one of the plurality of sensors 10702 based on one or more
of the learned received output data patterns 10718 and the state.
The state may correspond to an outcome relating to a machine in the
environment, an anticipated outcome relating to a machine in the
environment, an outcome relating to a process in the environment,
an anticipated outcome relating to a process in the environment,
and the like. The collection parameter may be a bandwidth
parameter, may be used to govern the multiplexing of a plurality of
the input sensors, may be a timing parameter, may relate to a
frequency range, may relate to the granularity of collection of
sensor data, is a storage parameter for the collected data. The
machine learning data analysis circuit may be structured to learn
received output data patterns 10718 by being seeded with a model
10720, which may be a physical model, an operational model, or a
system model. The machine learning data analysis circuit may be
structured to learn received output data patterns 10718 based on
the state. The data collection band circuit may alter the subset of
the plurality of sensors when the learned received output data
pattern does not reliably predict the state, which may include
discontinuing collection of data from the at least one subset.
[1031] The monitoring system 10700 may keep or modify operational
parameters of an item of equipment in the environment based on the
determined state. The controller 10706 may adjust the weighting of
the machine learning data analysis circuit 10712 based on the
learned received output data patterns 10718 or the state. The
controller 10706 may collect more/fewer data points from one or
more members of the at least one subset of plurality of sensors
10702 based on the learned received output data patterns 10718 or
the state. The controller 10706 may change a data storage technique
for the output data 10710 based on the learned received output data
patterns 10718 or the state. The controller 10706 may change a data
presentation mode or manner based on the learned received output
data patterns 10718 or the state. The controller 10706 may apply
one or more filters to the output data 10710. The controller 10706
may identify a new data collection band circuit 10708 based on one
or more of the learned received output data patterns 10718 and the
state. The controller 10706 may adjust the weights/biases of the
machine learning data analysis circuit 10712, such as in response
to the learned received output data patterns 10718, in response to
the accuracy of the prediction of an anticipated state by the
machine learning data analysis circuit, in response to the accuracy
of a classification of a state by the machine learning data
analysis circuit, and the like. The monitoring device 10700 may
remove or re-task under-utilized equipment based on one or more of
the learned received output data patterns 10718 and the state. The
machine learning data analysis circuit 10712 may include a neural
network expert system. At least one subset of the plurality of
sensors measures vibration and noise data. The machine learning
data analysis circuit 10712 may be structured to learn received
output data patterns 10718 indicative of progress/alignment with
one or more goals/guidelines, wherein progress/alignment of each
goal/guideline may be determined by a different subset of the
plurality of sensors. The machine learning data analysis circuit
10712 may be structured to learn received output data patterns
10718 indicative of an unknown variable. The machine learning data
analysis circuit 10712 may be structured to learn received output
data patterns 10718 indicative of a preferred input among available
inputs. The machine learning data analysis circuit 10712 may be
structured to learn received output data patterns 10718 indicative
of a preferred input data collection band among available input
data collection bands. The machine learning data analysis circuit
10712 may be disposed in part on a machine, on one or more data
collectors, in network infrastructure, in the cloud, or any
combination thereof.
[1032] In embodiments, a monitoring device for data collection in
an industrial environment may include a plurality of input sensors
10702 communicatively coupled to a controller 10706, the controller
10706 including a data collection band circuit 10708 structured to
determine at least one subset of the plurality of sensors 10702
from which to process output data 10710; and a machine learning
data analysis circuit 10712 structured to receive output data from
the at least one subset of the plurality of sensors 10702 and learn
received output data patterns 10718 indicative of a state, wherein
the data collection band circuit 10708 alters an aspect of the at
least one subset of the plurality of sensors 10702 based on one or
more of the learned received output data patterns 10718 and the
state. The aspect that the data collection band circuit 10708
alters is a number or a frequency of data points collected from one
or more members of the at least one subset of plurality of sensors
10702. The aspect that the data collection band circuit 10708
alters is a bandwidth parameter, a timing parameter, a frequency
range, a granularity of collection of sensor data, a storage
parameter for the collected data, and the like.
[1033] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712 structured to receive output data 10710 from the at
least one of the plurality of sensors 10702 and learn received
output data patterns indicative of a state, wherein the data
collection band circuit 10708 alters the at least one collection
parameter for the at least one of the plurality of sensors 10702
based on one or more of the learned received output data patterns
10718 and the state, and wherein the data collection band circuit
10708 alters the at least one of the plurality of sensors 10702
when the learned received output data pattern 10718 does not
reliably predict the state.
[1034] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712 structured to receive output data 10710 from the at
least one of the plurality of sensors 10702 and learn received
output data patterns 10718 indicative of a state, wherein the data
collection band circuit 10708 alters the at least one collection
parameter for the at least one of the plurality of sensors 10702
based on one or more of the learned received output data patterns
10718 and the state, and wherein the data collector 10704 collects
more or fewer data points from the at least one of the plurality of
sensors 10702 based on the learned received output data patterns
10718 or the state.
[1035] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712 structured to receive output data 10710 from the at
least one of the plurality of sensors 10702 and learn received
output data 10710 patterns indicative of a state, wherein the data
collection band circuit 10708 alters the at least one collection
parameter for the at least one of the plurality of sensors 10702
based on one or more of the learned received output data patterns
10718 and the state, and wherein the controller 10706 changes a
data storage technique for the output data 10710 based on the
learned received output data patterns 10718 or the state.
[1036] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712 structured to receive output data 10710 from the at
least one of the plurality of sensors 10702 and learn received
output data patterns 10718 indicative of a state, wherein the data
collection band circuit 10708 alters the at least one collection
parameter for the at least one of the plurality of sensors 10702
based on one or more of the learned received output data patterns
10718 and the state, and wherein the controller 10706 changes a
data presentation mode or manner based on the learned received
output data patterns 10718 or the state.
[1037] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712 structured to receive output data 10710 from the at
least one of the plurality of sensors 10702 and learn received
output data patterns 10718 indicative of a state, wherein the data
collection band circuit 10708 alters the at least one collection
parameter for the at least one of the plurality of sensors 10702
based on one or more of the learned received output data patterns
10718 and the state, and wherein the controller 10706 identifies a
new data collection band circuit 10708 based on one or more of the
learned received output data patterns 10718 and the state.
[1038] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712 structured to receive output data 10710 from the at
least one of the plurality of sensors 10702 and learn received
output data patterns 10718 indicative of a state, wherein the data
collection band circuit 10708 alters the at least one collection
parameter for the at least one of the plurality of sensors 10702
based on one or more of the learned received output data patterns
10718 and the state, and wherein the controller 10706 adjusts the
weights/biases of the machine learning data analysis circuit 10712.
The adjustment may be in response to the learned received output
data patterns, in response to the accuracy of the prediction of an
anticipated state by the machine learning data analysis circuit, in
response to the accuracy of a classification of a state by the
machine learning data analysis circuit, and the like.
[1039] In an embodiment, a monitoring system 10700 for data
collection in an industrial environment may include a plurality of
input sensors 10702 communicatively coupled to a data collector
10704 having a controller 10706, a data collection band circuit
10708 structured to determine at least one collection parameter for
at least one of the plurality of sensors 10702 from which to
process output data 10710, and a machine learning data analysis
circuit 10712. This machine learning data analysis circuit is
structured to receive output data 10710 from the at least one of
the plurality of sensors 10702 and learn received output data
patterns 10718 indicative of a state, wherein the data collection
band circuit 10708 alters the at least one collection parameter for
the at least one of the plurality of sensors 10702 based on one or
more of the learned received output data patterns 10718 and the
state, and wherein the machine learning data analysis circuit 10712
is structured to learn received output data patterns 10718
indicative of progress or alignment with one or more goals or
guidelines.
Clause 1. In embodiments, a monitoring system for data collection
in an industrial environment, comprising: a plurality of input
sensors communicatively coupled to a data collector having a
controller; a data collection band circuit structured to determine
at least one collection parameter for at least one of the plurality
of sensors from which to process output data; and a machine
learning data analysis circuit structured to receive output data
from the at least one of the plurality of sensors and learn
received output data patterns indicative of a state, wherein the
data collection band circuit alters the at least one collection
parameter for the at least one of the plurality of sensors based on
one or more of the learned received output data patterns and the
state. 2. The system of clause 1, wherein the state corresponds to
an outcome relating to a machine in the environment. 3. The system
of clause 1, wherein the state corresponds to an anticipated
outcome relating to a machine in the environment. 4. The system of
clause 1, wherein the state corresponds to an outcome relating to a
process in the environment. 5. The system of clause 1, wherein the
state corresponds to an anticipated outcome relating to a process
in the environment. 6. The system of clause 1, wherein the
collection parameter is a bandwidth parameter. 7. The system of
clause 1, wherein the collection parameter is used to govern the
multiplexing of a plurality of the input sensors. 8. The system of
clause 1, wherein the collection parameter is a timing parameter.
9. The system of clause 1, wherein the collection parameter relates
to a frequency range. 10. The system of clause 1, wherein the
collection parameter relates to the granularity of collection of
sensor data. 11. The system of clause 1, wherein the collection
parameter is a storage parameter for the collected data. 12. The
system of clause 1, wherein the machine learning data analysis
circuit is structured to learn received output data patterns by
being seeded with a model. 13. The system of clause 12, wherein the
model is a physical model, an operational model, or a system model.
14. The system of clause 1, wherein the machine learning data
analysis circuit is structured to learn received output data
patterns based on the state. 15. The system of clause 1, wherein
the data collection band circuit alters the subset of the plurality
of sensors when the learned received output data pattern does not
reliably predict the state. 16. The system of clause 15, wherein
altering at least one subset comprises discontinuing collection of
data from the at least one subset. 17. The system of clause 1,
wherein the monitoring system keeps or modifies operational
parameters of an item of equipment in the environment based on the
determined state. 18. The system of clause 1, wherein the
controller adjusts the weighting of the machine learning data
analysis circuit based on the learned received output data patterns
or the state. 19. The system of clause 1, wherein the controller
collects more or fewer data points from one or more members of the
at least one subset of plurality of sensors based on the learned
received output data patterns or the state. 20. The system of
clause 1, wherein the controller changes a data storage technique
for the output data based on the learned received output data
patterns or the state. 21. The system of clause 1, wherein the
controller changes a data presentation mode or manner based on the
learned received output data patterns or the state. 22. The system
of clause 1, wherein the controller applies one or more filters to
the output data. 23. The system of clause 1, wherein the controller
identifies a new data collection band circuit based on one or more
of the learned received output data patterns and the state. 24. The
system of clause 1, wherein the controller adjusts the
weights/biases of the machine learning data analysis circuit. 25.
The system of clause 24, wherein the adjustment is in response to
the learned received output data patterns. 26. The system of clause
24, wherein the adjustment is in response to the accuracy of the
prediction of an anticipated state by the machine learning data
analysis circuit. 27. The system of clause 24, wherein the
adjustment is in response to the accuracy of a classification of a
state by the machine learning data analysis circuit. 28. The system
of clause 1, wherein the monitoring device removes/re-tasks
under-utilized equipment based on one or more of the learned
received output data patterns and the state. 29. The system of
clause 1, wherein the machine learning data analysis circuit
comprises a neural network expert system. 30. The system of clause
1, wherein the at least one subset of the plurality of sensors
measure vibration and noise data. 31. The system of clause 1,
wherein the machine learning data analysis circuit is structured to
learn received output data patterns indicative of
progress/alignment with one or more goals/guidelines. 32. The
system of clause 31, wherein progress/alignment of each
goal/guideline is determined by a different subset of the plurality
of sensors. 33. The system of clause 1, wherein the machine
learning data analysis circuit is structured to learn received
output data patterns indicative of an unknown variable. 34. The
system of clause 1, wherein the machine learning data analysis
circuit is structured to learn received output data patterns
indicative of a preferred input among available inputs. 35. The
system of clause 1, wherein the machine learning data analysis
circuit is structured to learn received output data patterns
indicative of a preferred input data collection band among
available input data collection bands. 36. The system of clause 1,
wherein the machine learning data analysis circuit is disposed in
part on a machine, on one or more data collectors, in network
infrastructure, in the cloud, or any combination thereof. 37. A
monitoring device for data collection in an industrial environment,
comprising: a plurality of input sensors communicatively coupled to
a controller, the controller comprising: a data collection band
circuit structured to determine at least one subset of the
plurality of sensors from which to process output data; and a
machine learning data analysis circuit structured to receive output
data from the at least one subset of the plurality of sensors and
learn received output data patterns indicative of a state, wherein
the data collection band circuit alters an aspect of the at least
one subset of the plurality of sensors based on one or more of the
learned received output data patterns and the state. 38. The system
of clause 37, wherein the aspect that the data collection band
circuit alters is a number of data points collected from one or
more members of the at least one subset of plurality of sensors.
39. The system of clause 37, wherein the aspect that the data
collection band circuit alters is a frequency of data points
collected from one or more members of the at least one subset of
plurality of sensors. 40. The system of clause 37, wherein the
aspect that the data collection band circuit alters is a bandwidth
parameter. 41. The system of clause 37, wherein the aspect that the
data collection band circuit alters is a timing parameter. 42. The
system of clause 37, wherein the aspect that the data collection
band circuit alters relates to a frequency range. 43. The system of
clause 37, wherein the aspect that the data collection band circuit
alters relates to the granularity of collection of sensor data. 44.
The system of clause 37, wherein the collection parameter is a
storage parameter for the collected data. 45. A monitoring system
for data collection in an industrial environment, comprising: a
plurality of input sensors communicatively coupled to a data
collector having a controller; a data collection band circuit
structured to determine at least one collection parameter for at
least one of the plurality of sensors from which to process output
data; and a machine learning data analysis circuit structured to
receive output data from the at least one of the plurality of
sensors and learn received output data patterns indicative of a
state, wherein the data collection band circuit alters the at least
one collection parameter for the at least one of the plurality of
sensors based on one or more of the learned received output data
patterns and the state, and wherein the data collection band
circuit alters the at least one of the plurality of sensors when
the learned received output data pattern does not reliably predict
the state. 46. A monitoring system for data collection in an
industrial environment, comprising: a plurality of input sensors
communicatively coupled to a data collector having a controller; a
data collection band circuit structured to determine at least one
collection parameter for at least one of the plurality of sensors
from which to process output data; and a machine learning data
analysis circuit structured to receive output data from the at
least one of the plurality of sensors and learn received output
data patterns indicative of a state, wherein the data collection
band circuit alters the at least one collection parameter for the
at least one of the plurality of sensors based on one or more of
the learned received output data patterns and the state, and
wherein the data collector collects more or fewer data points from
the at least one of the plurality of sensors based on the learned
received output data patterns or the state. 47. A monitoring system
for data collection in an industrial environment, comprising: a
plurality of input sensors communicatively coupled to a data
collector having a controller; a data collection band circuit
structured to determine at least one collection parameter for at
least one of the plurality of sensors from which to process output
data; and a machine learning data analysis circuit structured to
receive output data from the at least one of the plurality of
sensors and learn received output data patterns indicative of a
state, wherein the data collection band circuit alters the at least
one collection parameter for the at least one of the plurality of
sensors based on one or more of the learned received output data
patterns and the state, and wherein the controller changes a data
storage technique for the output data based on the learned received
output data patterns or the state. 48. A monitoring system for data
collection in an industrial environment, comprising: a plurality of
input sensors communicatively coupled to a data collector having a
controller; a data collection band circuit structured to determine
at least one collection parameter for at least one of the plurality
of sensors from which to process output data; and a machine
learning data analysis circuit structured to receive output data
from the at least one of the plurality of sensors and learn
received output data patterns indicative of a state, wherein the
data collection band circuit alters the at least one collection
parameter for the at least one of the plurality of sensors based on
one or more of the learned received output data patterns and the
state, and wherein the controller changes a data presentation mode
or manner based on the learned received output data patterns or the
state. 49. A monitoring system for data collection in an industrial
environment, comprising: a plurality of input sensors
communicatively coupled to a data collector having a controller; a
data collection band circuit structured to determine at least one
collection parameter for at least one of the plurality of sensors
from which to process output data; and a machine learning data
analysis circuit structured to receive output data from the at
least one of the plurality of sensors and learn received output
data patterns indicative of a state, wherein the data collection
band circuit alters the at least one collection parameter for the
at least one of the plurality of sensors based on one or more of
the learned received output data patterns and the state, and
wherein the controller identifies a new data collection band
circuit based on one or more of the learned received output data
patterns and the state. 50. A monitoring system for data collection
in an industrial environment, comprising: a plurality of input
sensors communicatively coupled to a data collector having a
controller; a data collection band circuit structured to determine
at least one collection parameter for at least one of the plurality
of sensors from which to process output data; and a machine
learning data analysis circuit structured to receive output data
from the at least one of the plurality of sensors and learn
received output data patterns indicative of a state, wherein the
data collection band circuit alters the at least one collection
parameter for the at least one of the plurality of sensors based on
one or more of the learned received output data patterns and the
state, and wherein the controller adjusts the weights/biases of the
machine learning data analysis circuit. 51. The system of clause
50, wherein the adjustment is in response to the learned received
output data patterns. 52. The system of clause 50, wherein the
adjustment is in response to the accuracy of the prediction of an
anticipated state by the machine learning data analysis circuit.
53. The system of clause 50, wherein the adjustment is in response
to the accuracy of a classification of a state by the machine
learning data analysis circuit. 54. A monitoring system for data
collection in an industrial environment, comprising: a plurality of
input sensors communicatively coupled to a data collector having a
controller; a data collection band circuit structured to determine
at least one collection parameter for at least one of the plurality
of sensors from which to process output data; and a machine
learning data analysis circuit structured to receive output data
from the at least one of the plurality of sensors and learn
received output data patterns indicative of a state, wherein the
data collection band circuit alters the at least one collection
parameter for the at least one of the plurality of sensors based on
one or more of the learned received output data patterns and the
state, and wherein the machine learning data analysis circuit is
structured to learn received output data patterns indicative of
progress or alignment with one or more goals or guidelines.
[1040] As described elsewhere herein, an expert system in an
industrial environment may use sensor data to make predictions
about outcomes or states of the environment or items in the
environment. Data collection may be of various types of data (e.g.,
vibration data, noise data and other sensor data of the types
described throughout this disclosure) for event detection, state
detection, and the like. For example, the expert system may utilize
ambient noise, or the overall sound environment of the area and/or
overall vibration of the device of interest, optionally in
conjunction with other sensor data, in detecting or predicting
events or states. For example, a reciprocating compressor in a
refinery, which may generate its own vibration, may also have an
ambient vibration through contact with other aspects of the
system.
[1041] In embodiments, all three types of noise (ambient noise,
local noise and vibration noise) including various subsets thereof
and combinations with other types of data, may be organized into
large data sets, along with measured results, that are processed by
a "deep learning" machine/expert system that learns to predict one
or more states (e.g., maintenance, failure, or operational) or
overall outcomes, such as by learning from human supervision or
from other feedback, such as feedback from one or more of the
systems described throughout this disclosure and the documents
incorporated by reference herein.
[1042] Throughout this disclosure, various examples will involve
machines, components, equipment, assemblies, and the like, and it
should be understood that the disclosure could apply to any of the
aforementioned. Elements of these machines operating in an
industrial environment (e.g., rotating elements, reciprocating
elements, swinging elements, flexing elements, flowing elements,
suspending elements, floating elements, bouncing elements, bearing
elements, etc.) may generate vibrations that may be of a specific
frequency and/or amplitude typical of the element when the element
is in a given operating condition or state (e.g., a normal mode of
operation of a machine at a given speed, in a given gear, or the
like). Changes in a parameter of the vibration may be indicative or
predictive of a state or outcome of the machine. Various sensors
may be useful in measuring vibration, such as accelerometers,
velocity transducers, imaging sensors, acoustic sensors, and
displacement probes, which may collectively be known as vibration
sensors. Vibration sensors may be mounted to the machine, such as
permanently or temporarily (e.g., adhesive, hook-and-loop, or
magnetic attachment), or may be disposed on a mobile or portable
data collector. Sensed conditions may be compared to historical
data to identify or predict a state, condition or outcome. Typical
faults that can be identified using vibration analysis include:
machine out of balance, machine out of alignment, resonance, bent
shafts, gear mesh disturbances, blade pass disturbances, vane pass
disturbances, recirculation & cavitation, motor faults (rotor
& stator), bearing failures, mechanical looseness, critical
machine speeds, and the like, as well as excessive friction, clutch
slipping, belt problems, suspension and shock absorption problems,
valve and other fluid leaks, under-pressure states in lubrication
and other fluid systems, overheating (such as due to many of the
above), blockage or freezing of engagement of mechanical systems,
interference effects, and other faults described throughout this
disclosure and in the documents incorporated by reference.
[1043] Given that machines are frequently found adjacent to or
working in concert with other machinery, measuring the vibration of
the machine may be complicated by the presence of various noise
components in the environment or associated vibrations that the
machine may be subjected to. Indeed, the ambient and/or local
environment may have its own vibration and/or noise pattern that
may be known. In embodiments, the combination of vibration data
with ambient and/or local noise or other ambient sensed conditions
may form its own pattern, as will be further described herein.
[1044] In embodiments, measuring vibration noise may involve one or
more vibration sensors on or in a machine to measure vibration
noise of the machine that occurs continuously or periodically.
Analysis of the vibration noise may be performed, such as
filtering, signal conditioning, spectral analysis, trend analysis,
and the like. Analysis may be performed on aggregate or individual
sensor measurements to isolate vibration noise of equipment to
obtain a characteristic vibration, vibration pattern or "vibration
fingerprint" of the machine. The vibration fingerprints may be
stored in a data structure, or library, of vibration fingerprints.
The vibration fingerprints may include frequencies, spectra (i.e.,
frequency vs. amplitude), velocities, peak locations, wave peak
shapes, waveform shapes, wave envelope shapes, accelerations, phase
information, phase shifts (including complex phase measurements)
and the like. Vibration fingerprints may be stored in the library
in association with a parameter by which it may be searched or
sorted. The parameters may include a brand or type of
machine/component/equipment, location of sensor(s) attachment or
placement, duty cycle of the equipment/machine, load sharing of the
equipment/machine, dynamic interactions with other devices, RPM,
flow rate, pressure, other vibration driving characteristic,
voltage of line power, age of equipment, time of operation, known
neighboring equipment, associated auxiliary equipment/components,
size of space equipment is in, material of platform for equipment,
heat flux, magnetic fields, electrical fields, currents, voltage,
capacitance, inductance, aspect of a product, and combinations
(e.g., simple ratios) of the same. Vibration fingerprints may be
obtained for machines under normal operation or for other periods
of operation (e.g., off-nominal operation, malfunction, maintenance
needed, faulty component, incorrect parameters of operation, other
conditions, etc.) and can be stored in the library for comparison
to current data. The library of vibration fingerprints may be
stored as indicators with associated predictions, states, outcomes
and/or events. Trend analysis data of measured vibration
fingerprints can indicate time between maintenance events/failure
events.
[1045] In embodiments, vibration noise may be used by the expert
system to confirm the status of a machine, such as a favorable
operation, a production rate, a generation rate, an operational
efficiency, a financial efficiency (e.g., output per cost), a power
efficiency, and the like. In embodiments, the expert system may
make a comparison of the vibration noise with a stored vibration
fingerprint. In other embodiments, the expert system may be seeded
with vibration noise and initial feedback on states and outcomes in
order to learn to predict other states and outcomes. For example, a
center pivot irrigation system may be remotely monitored by
attached vibration sensors to provide a measured vibration noise
that can be compared to a library of vibration fingerprints to
confirm that the system is operating normally. If the system is not
operating normally, the expert system may automatically dispatch a
field crew or drone to investigate. In another example of a vacuum
distillation unit in a refinery, the vibration noise may be
compared, such as by the expert system, to stored vibration
fingerprints in a library to confirm a production rate of diesel.
In a further example, the expert system may be seeded with
vibration noise for a pipeline under conditions of a normal
production rate and as the expert system iterates with current data
(e.g., altered vibration noise, and possibly other altered
parameters), it may predict that the production rate has increased
as caused by the alterations. Measurements may be continually
analyzed in this way to remotely monitor operation.
[1046] In embodiments, vibration noise may be compared, such as by
the expert system, to stored vibration fingerprints and associated
states and outcomes in the library, or alternatively, may be used
to seed an expert system to predict when maintenance is required
(e.g., off-nominal measurement, artifacts in signal, etc.), such as
when vibration noise is matched to a condition when the
equipment/component required maintenance, vibration noise exceeds a
threshold/limit, vibration noise exceeds a threshold/limit or
matches a library vibration fingerprint together with one or more
additional parameters, as described herein. For example, when the
vibration fingerprint from a turbine agitator in a pharmaceutical
processing plant matches a vibration fingerprint for a turbine
agitator when it required a replacement bearing, the expert system
may cause an action to occur, such as immediately shutting down the
agitator or scheduling its shutdown and maintenance.
[1047] In embodiments, vibration noise may be compared, such as by
the expert system, to stored vibration fingerprints and associated
states and outcomes in the library, or alternatively, may be used
to seed an expert system to predict a failure or an imminent
failure. For example, vibration noise from a gas agitator in a
pharmaceutical processing plant may be matched to a condition when
the agitator previously failed or was about to fail. In this
example, the expert system may immediately shut down the agitator,
schedule its shutdown, or cause a backup agitator to come online.
In another example, vibration noise from a pump blasting liquid
agitator in a chemical processing plant may exceed a threshold or
limit and the expert system may cause an investigation into the
cause of the excess vibration noise, shut down the agitator, or the
like. In another example, vibration noise from an anchor agitator
in a pharmaceutical processing plant may exceed a threshold/limit
or match a library vibration fingerprint together with one or more
additional parameters (see parameters herein), such as a decreased
flow rate, increased temperature, or the like. Using vibration
noise taken together with the parameters, the expert system may
more reliably predict the failure or imminent failure.
[1048] In embodiments, vibration noise may be compared, such as by
the expert system, to stored vibration fingerprints and associated
states and outcomes in the library, or alternatively, may be used
to seed an expert system to predict or diagnose a problem (e.g.,
unbalanced, misaligned, worn, or damaged) with the equipment or an
external source contributing vibration noise to the equipment. For
example, when the vibration noise from a paddle-type agitator mixer
matches a vibration fingerprint from a prior imbalance, the expert
system may immediately shut down the mixer.
[1049] In embodiments, when the expert system makes a prediction of
an outcome or state using vibration noise, the expert system may
perform a downstream action, or cause it to be performed.
Downstream actions may include: triggering an alert of a failure,
imminent failure, or maintenance event; shutting down
equipment/component; initiating maintenance/lubrication/alignment;
deploying a field technician; recommending a vibration
absorption/dampening device; modifying a process to utilize backup
equipment/component; modifying a process to preserve
products/reactants, etc.; generating/modifying a maintenance
schedule; coupling the vibration fingerprint with duty cycle of the
equipment, RPM, flow rate, pressure, temperature or other
vibration-driving characteristic to obtain equipment/component
status and generate a report, and the like. For example, vibration
noise for a catalytic reactor in a chemical processing plant may be
matched to a condition when the catalytic reactor required
maintenance. Based on this predicted state of required maintenance,
the expert system may deploy a field technician to perform the
maintenance.
[1050] In embodiments, the library may be updated if a changed
parameter resulted in a new vibration fingerprint, or if a
predicted outcome or state did not occur in the absence of
mitigation. In embodiments, the library may be updated if a
vibration fingerprint was associated with an alternative state than
what was predicted by the library. The update may occur after just
one time that the state that actually occurred did not match the
predicted state from the library. In other embodiments, it may
occur after a threshold number of times. In embodiments, the
library may be updated to apply one or more rules for comparison,
such as rules that govern how many parameters to match along with
the vibration fingerprint, or the standard deviation for the match
in order to accept the predicted outcome.
[1051] In embodiments, vibration noise may be compared, such as by
the expert system, to stored vibration fingerprints and associated
states and outcomes in the library, or alternatively, may be used
to seed an expert system to determine if a change in a system
parameter external or internal to the machine has an effect on its
intrinsic operation. In embodiments, a change in one or more of a
temperature, flow rate, materials in use, duration of use, power
source, installation, or other parameter (see parameters above) may
alter the vibration fingerprint of a machine. For example, in a
pressure reactor in a chemical processing plant, the flow rate and
a reactant may be changed. The changes may alter the vibration
fingerprint of the machine such that the vibration fingerprint
stored in the library for normal operation is no longer
correct.
[1052] Ambient noise, or the overall sound environment of the area
and/or overall vibration of the device of interest, optionally in
conjunction with other ambient sensed conditions, may be used in
detecting or predicting events, outcomes, or states. Ambient noise
may be measured by a microphone, ultrasound sensors, acoustic wave
sensors, optical vibration sensors (e.g., using a camera to see
oscillations that produce noise), or "deep learning" neural
networks involving various sensor arrays that learn, using large
data sets, to identify patterns, sounds types, noise types, etc. In
an embodiment, the ambient sensed condition may relate to motion
detection. For example, the motion may be a platform motion (e.g.,
vehicle, oil platform, suspended platform on land, etc.) or an
object motion (e.g., moving equipment, people, robots, parts (e.g.,
fan blades or turbine blades), etc.). In an embodiment, the ambient
sensed condition may be sensed by imaging, such as to detect a
location and nature of various machines, equipment, and other
objects, such as ones that might impact local vibration. In an
embodiment, the ambient sensed condition may be sensed by thermal
detection and imaging (e.g., for presence of people; presence of
heat sources that may affect performance parameters, etc.). In an
embodiment, the ambient sensed condition may be sensed by field
detection (e.g., electrical, magnetic, etc.). In an embodiment, the
ambient sensed condition may be sensed by chemical detection (e.g.,
smoke, other conditions). Any sensor data may be used by the expert
system to provide an ambient sensed condition for analysis along
with the vibration fingerprint to predict an outcome, event, or
state. For example, an ambient sensed condition near a stirrer or
mixer in a food processing plant may be the operation of a space
heater during winter months, wherein the ambient sensed condition
may include an ambient noise and an ambient temperature.
[1053] In an aspect, local noise may be the noise or vibration
environment which is ambient, but known to be locally generated.
The expert system may filter out ambient noise, employ common mode
noise removal, and/or physically isolate the sensing
environment.
[1054] In embodiments, a system for data collection in an
industrial environment may use ambient, local and vibration noise
for prediction of outcomes, events, and states. A library may be
populated with each of the three noise types for various conditions
(e.g., start up, shut down, normal operation, other periods of
operation as described elsewhere herein). In other embodiments, the
library may be populated with noise patterns representing the
aggregate ambient, local, and/or vibration noise. Analysis (e.g.,
filtering, signal conditioning, spectral analysis, trend analysis)
may be performed on the aggregate noise to obtain a characteristic
noise pattern and identify changes in noise pattern as possible
indicators of a changed condition. A library of noise patterns may
be generated with established vibration fingerprints and local and
ambient noise that can be sorted by a parameter (see parameters
herein), or other parameters/features of the local and ambient
environment (e.g., company type, industry type, products, robotic
handling unit present/not present, operating environment, flow
rates, production rates, brand or type of auxiliary equipment
(e.g., filters, seals, coupled machinery)). The library of noise
patterns may be used by an expert system, such as one with machine
learning capacity, to confirm a status of a machine, predict when
maintenance is required (e.g., off-nominal measurement, artifacts
in signal), predict a failure or an imminent failure,
predict/diagnose a problem, and the like.
[1055] Based on a current noise pattern, the library may be
consulted or used to seed an expert system to predict an outcome,
event, or state based on the noise pattern. Based on the
prediction, the expert system may one or more of trigger an alert
of a failure, imminent failure, or maintenance event, shut down
equipment/component/line, initiate
maintenance/lubrication/alignment, deploy a field technician,
recommend a vibration absorption/dampening device, modify a process
to utilize backup equipment/component, modify a process to preserve
products/reactants, etc., generate/modify a maintenance schedule,
or the like.
[1056] For example, a noise pattern for a thermic heating system in
a pharmaceutical plant or cooking system may include local,
ambient, and vibration noise. The ambient noise may be a result of,
for example, various pumps to pump fuel into the system. Local
noise may be a result of a local security camera chirping with
every detection of motion. Vibration noise may result from the
combustion machinery used to heat the thermal fluid. These noise
sources may form a noise pattern which may be associated with a
state of the thermic system. The noise pattern and associated state
may be stored in a library. An expert system used to monitor the
state of the thermic heating system may be seeded with noise
patterns and associated states from the library. As current data
are received into the expert system, it may predict a state based
on having learned noise patterns and associated states.
[1057] In another example, a noise pattern for boiler feed water in
a refinery may include local and ambient noise. The local noise may
be attributed to the operation of, for example, a feed pump feeding
the feed water into a steam drum. The ambient noise may be
attributed to nearby fans. These noise sources may form a noise
pattern which may be associated with a state of the boiler feed
water. The noise pattern and associated state may be stored in a
library. An expert system used to monitor the state of the boiler
may be seeded with noise patterns and associated states from the
library. As current data are received into the expert system, it
may predict a state based on having learned noise patterns and
associated states.
[1058] In yet another example, a noise pattern for a storage tank
in a refinery may include local, ambient, and vibration noise. The
ambient noise may be a result of, for example, a pump that pumps a
product into the tank. Local noise may be a result of a fan
ventilating the tank room. Vibration noise may result from line
noise of a power supply into the storage tank. These noise sources
may form a noise pattern which may be associated with a state of
the storage tank. The noise pattern and associated state may be
stored in a library. An expert system used to monitor the state of
the storage tank may be seeded with noise patterns and associated
states from the library. As current data are received into the
expert system, it may predict a state based on having learned noise
patterns and associated states.
[1059] In another example, a noise pattern for condensate/make-up
water system in a power station may include vibration and ambient
noise. The ambient noise may be attributed to nearby fans. The
vibration noise may be attributed to the operation of the
condenser. These noise sources may form a noise pattern which may
be associated with a state of the condensate/make-up water system.
The noise pattern and associated state may be stored in a library.
An expert system used to monitor the state of the
condensate/make-up water system may be seeded with noise patterns
and associated states from the library. As current data are
received into the expert system, it may predict a state based on
having learned noise patterns and associated states.
[1060] A library of noise patterns may be updated if a changed
parameter resulted in a new noise pattern or if a predicted outcome
or state did not occur in the absence of mitigation of a diagnosed
problem. A library of noise patterns may be updated if a noise
pattern resulted in an alternative state than what was predicted by
the library. The update may occur after just one time that the
state that actually occurred did not match the predicted state from
the library. In other embodiments, it may occur after a threshold
number of times. In embodiments, the library may be updated to
apply one or more rules for comparison, such as rules that govern
how many parameters to match along with the noise pattern, or the
standard deviation for the match in order to accept the predicted
outcome. For example, a baffle may be replaced in a static agitator
in a pharmaceutical processing plant which may result in a changed
noise pattern. In another example, as the seal on a pressure cooker
in a food processing plant ages, the noise pattern associated with
the pressure cooker may change.
[1061] In embodiments, the library of vibration fingerprints, noise
sources and/or noise patterns may be available for subscription.
The libraries may be used in offset systems to improve operation of
the local system. Subscribers may subscribe at any level (e.g.,
component, machinery, installation, etc.) in order to access data
that would normally not be available to them, such as because it is
from a competitor, or is from an installation of the machinery in a
different industry not typically considered. Subscribers may search
on indicators/predictors based on or filtered by system conditions,
or update an indicator/predictor with proprietary data to customize
the library. The library may further include parameters and
metadata auto-generated by deployed sensors throughout an
installation, onboard diagnostic systems and instrumentation and
sensors, ambient sensors in the environment, sensors (e.g., in
flexible sets) that can be put into place temporarily, such as in
one or more mobile data collectors, sensors that can be put into
place for longer term use, such as being attached to points of
interest on devices or systems, and the like.
[1062] In embodiments, a third party (e.g., RMOs, manufacturers)
can aggregate data at the component level, equipment level,
factory/installation level and provide a statistically valid data
set against which to optimize their own systems. For example, when
a new installation of a machine is contemplated, it may be
beneficial to review a library for best data points to acquire in
making state predictions. For example, a particular sensor package
may be recommended to reliably determine if there will be a
failure. For example, if vibration noise of equipment coupled with
particular levels of local noise or other ambient sensed conditions
reliably is an indicator of imminent failure, a given vibration
transducer/temp/microphone package observing those elements may be
recommended for the installation. Knowing such information may
inform the choice to rent or buy a piece of machinery or associated
warranties and service plans, such as based on knowing the quantity
and depth of information that may be needed to reliably maintain
the machinery.
[1063] In embodiments, manufacturers may utilize the library to
rapidly collect in-service information for machines to draft
engineering specifications for new customers.
[1064] In embodiments, noise and vibration data may be used to
remotely monitor installs and automatically dispatch a field
crew.
[1065] In embodiments, noise and vibration data may be used to
audit a system. For example, equipment running outside the range of
a licensed duty cycle may be detected by a suite of vibration
sensors and/or ambient/local noise sensors. In embodiments, alerts
may be triggered of potential out-of-warranty violations based on
data from vibration sensors and/or ambient/local noise sensors.
[1066] In embodiments, noise and vibration data may be used in
maintenance. This may be particularly useful where multiple
machines are deployed that may vibrationally interact with the
environment, such as two large generating machines on the same
floor or platform with each other, such as in power generation
plants.
[1067] In embodiments, a monitoring system 10800 for data
collection in an industrial environment, may include a plurality of
sensors 10802 selected among vibration sensors, ambient environment
condition sensors and local sensors for collecting non-vibration
data proximal to a machine in the environment, the plurality of
sensors 10802 communicatively coupled to a data collector 10804, a
data collection circuit 10808 structured to collect output data
10810 from the plurality of sensors 10802, and a machine learning
data analysis circuit 10812 structured to receive the output data
10810 and learn received output data patterns 10814 predictive of
at least one of an outcome and a state. The state may correspond to
an outcome relating to a machine in the environment, an anticipated
outcome relating to a machine in the environment, an outcome
relating to a process in the environment, or an anticipated outcome
relating to a process in the environment. The system may be
deployed on the data collector 10804 or distributed between the
data collector 10804 and a remote infrastructure. The data
collector 10804 may include the data collection circuit 10808. The
ambient environment condition or local sensors include one or more
of a noise sensor, a temperature sensor, a flow sensor, a pressure
sensor, a chemical sensor, a vibration sensor, an acceleration
sensor, an accelerometer, a Pressure sensor, a force sensor, a
position sensor, a location sensor, a velocity sensor, a
displacement sensor, a temperature sensor, a thermographic sensor,
a heat flux sensor, a tachometer sensor, a motion sensor, a
magnetic field sensor, an electrical field sensor, a galvanic
sensor, a current sensor, a flow sensor, a gaseous flow sensor, a
non-gaseous fluid flow sensor, a heat flow sensor, a particulate
flow sensor, a level sensor, a proximity sensor, a toxic gas
sensor, a chemical sensor, a CBRNE sensor, a pH sensor, a
hygrometer, a moisture sensor, a densitometer, an imaging sensor, a
camera, an SSR, a triax probe, an ultrasonic sensor, a touch
sensor, a microphone, a capacitive sensor, a strain gauge, an EMF
meter, and the like.
[1068] In embodiments, a monitoring system 10800 for data
collection in an industrial environment may include a data
collection circuit 10808 structured to collect output data 10810
from a plurality of sensors 10802 selected among vibration sensors,
ambient environment condition sensors and local sensors for
collecting non-vibration data proximal to a machine in the
environment, the plurality of sensors 10802 communicatively coupled
to a data collection circuit 10808, and a machine learning data
analysis circuit 10812 structured to receive the output data 10810
and learn received output data patterns 10814 predictive of at
least one of an outcome and a state, wherein the monitoring system
10800 is structured to determine if the output data matches a
learned received output data pattern. The machine learning data
analysis circuit 10812 may be structured to learn received output
data patterns 10814 by being seeded with a model 10816. The model
10816 may be a physical model, an operational model, or a system
model. The machine learning data analysis circuit 10812 may be
structured to learn received output data patterns 10814 based on
the outcome or the state. The monitoring system 10700 keeps or
modifies operational parameters or equipment based on the predicted
outcome or the state. The data collection circuit 10808 collects
more or fewer data points from one or more of the plurality of
sensors 10802 based on the learned received output data patterns
10814, the outcome or the state. The data collection circuit 10808
changes a data storage technique for the output data based on the
learned received output data patterns 10814, the outcome, or the
state. The data collector 10804 changes a data presentation mode or
manner based on the learned received output data patterns 10814,
the outcome, or the state. The data collection circuit 10808
applies one or more filters (low pass, high pass, band pass, etc.)
to the output data. The data collection circuit 10808 adjusts the
weights/biases of the machine learning data analysis circuit 10812,
such as in response to the learned received output data patterns
10814. The monitoring system 10800 removes/re-tasks under-utilized
equipment based on one or more of the learned received output data
patterns 10814, the outcome, or the state. The machine learning
data analysis circuit 10812 may include a neural network expert
system. The machine learning data analysis circuit 10812 may be
structured to learn received output data patterns 10814 indicative
of progress/alignment with one or more goals/guidelines, wherein
progress/alignment of each goal/guideline is determined by a
different subset of the plurality of sensors 10802. The machine
learning data analysis circuit 10812 may be structured to learn
received output data patterns 10814 indicative of an unknown
variable. The machine learning data analysis circuit 10812 may be
structured to learn received output data patterns 10814 indicative
of a preferred input sensor among available input sensors. The
machine learning data analysis circuit 10812 may be disposed in
part on a machine, on one or more data collection circuits 10808,
in network infrastructure, in the cloud, or any combination
thereof. The output data 10810 from the vibration sensors forms a
vibration fingerprint, which may include one or more of a
frequency, a spectrum, a velocity, a peak location, a wave peak
shape, a waveform shape, a wave envelope shape, an acceleration, a
phase information, and a phase shift. The data collection circuit
10808 may apply a rule regarding how many parameters of the
vibration fingerprint to match or the standard deviation for the
match in order to identify a match between the output data 10810
and the learned received output data pattern. The state may be one
of a normal operation, a maintenance required, a failure, or an
imminent failure. The monitoring system 10800 may trigger an alert,
shut down equipment/component/line, initiate
maintenance/lubrication/alignment based on the predicted outcome or
state, deploy a field technician based on the predicted outcome or
state, recommend a vibration absorption/dampening device based on
the predicted outcome or state, modify a process to utilize backup
equipment/component based on the predicted outcome or state, and
the like. The monitoring system 10800 may modify a process to
preserve products/reactants, etc. based on the predicted outcome or
state. The monitoring system 10800 may generate or modify a
maintenance schedule based on the predicted outcome or state. The
data collection circuit 10808 may include the data collection
circuit 10808. The system may be deployed on the data collection
circuit 10808 or distributed between the data collection circuit
10808 and a remote infrastructure.
[1069] In embodiments, a monitoring system 10800 for data
collection in an industrial environment may include a data
collection circuit 10808 structured to collect output data 10810
from a plurality of sensors 10802 selected among vibration sensors,
ambient environment condition sensors and local sensors for
collecting non-vibration data proximal to a machine in the
environment, the plurality of sensors 10802 communicatively coupled
to the data collection circuit 10808, and a machine learning data
analysis circuit 10812 structured to receive the output data 10810
and learn received output data patterns 10814 predictive of at
least one of an outcome and a state, wherein the monitoring system
10800 is structured to determine if the output data matches a
learned received output data pattern and keep or modify operational
parameters or equipment based on the determination.
[1070] In embodiments, a monitoring system 10800 for data
collection in an industrial environment may include a data
collection circuit 10808 structured to collect output data 10810
from the plurality of sensors 10802 selected among vibration
sensors, ambient environment condition sensors and local sensors
for collecting non-vibration data proximal to a machine in the
environment, the plurality of sensors 10802 communicatively coupled
to the data collection circuit 10808, and a machine learning data
analysis circuit 10812 structured to receive the output data 10810
and learn received output data patterns 10814 predictive of at
least one of an outcome and a state, wherein the output data 10810
from the vibration sensors forms a vibration fingerprint. The
vibration fingerprint may include one or more of a frequency, a
spectrum, a velocity, a peak location, a wave peak shape, a
waveform shape, a wave envelope shape, an acceleration, a phase
information, and a phase shift. The data collection circuit 10808
may apply a rule regarding how many parameters of the vibration
fingerprint to match or the standard deviation for the match in
order to identify a match between the output data 10810 and the
learned received output data pattern. The monitoring system 10800
may be structured to determine if the output data matches a learned
received output data pattern and keep or modify operational
parameters or equipment based on the determination.
[1071] In embodiments, a monitoring system 10800 for data
collection in an industrial environment may include a data
collection band circuit 10818 that identifies a subset of the
plurality of sensors 10802 from which to process output data, the
sensors selected among vibration sensors, ambient environment
condition sensors and local sensors for collecting non-vibration
data proximal to a machine in the environment, the plurality of
sensors 10802 communicatively coupled to a data collection band
circuit 10818, a data collection circuit 10808 structured to
collect the output data 10810 from the subset of plurality of
sensors 10802, and a machine learning data analysis circuit 10812
structured to receive the output data 10810 and learn received
output data patterns 10814 predictive of at least one of an outcome
and a state, wherein when the learned received output data patterns
10814 do not reliably predict the outcome or the state, the data
collection band circuit 10818 alters at least one parameter of at
least one of the plurality of sensors 10802. A controller 10806
identifies a new data collection band circuit 10818 based on one or
more of the learned received output data patterns 10814 and the
outcome or state. The machine learning data analysis circuit 10812
may be further structured to learn received output data patterns
10814 indicative of a preferred input data collection band among
available input data collection bands. The system may be deployed
on the data collection circuit 10808 or distributed between the
data collection circuit 10808 and a remote infrastructure.
[1072] In embodiments, a monitoring system for data collection in
an industrial environment may include a data collection circuit
10808 structured to collect output data 10810 from a plurality of
sensors 10802, the sensors selected among vibration sensors,
ambient environment condition sensors and local sensors for
collecting non-vibration data proximal to a machine in the
environment, the plurality of sensors 10802 communicatively coupled
to the data collection circuit 10808, wherein the output data 10810
from the vibration sensors is in the form of a vibration
fingerprint, a data structure 10820 comprising a plurality of
vibration fingerprints and associated outcomes, and a machine
learning data analysis circuit 10812 structured to receive the
output data 10810 and learn received output data patterns 10814
predictive of an outcome or a state based on processing of the
vibration fingerprints. The machine learning data analysis circuit
10812 may be seeded with one of the plurality of vibration
fingerprints from the data structure 10820. The data structure
10820 may be updated if a changed parameter resulted in a new
vibration fingerprint or if a predicted outcome did not occur in
the absence of mitigation. The data structure 10820 may be updated
when the learned received output data patterns 10814 do not
reliably predict the outcome or the state. The system may be
deployed on the data collection circuit or distributed between the
data collection circuit and a remote infrastructure.
[1073] In embodiments, a monitoring system 10800 for data
collection in an industrial environment may include a data
collection circuit 10808 structured to collect output data 10810
from a plurality of sensors 10802 selected among vibration sensors,
ambient environment condition sensors and local sensors for
collecting non-vibration data proximal to a machine in the
environment, the plurality of sensors 10802 communicatively coupled
to a data collection circuit 10808, wherein the output data 10810
from the plurality of sensors 10802 is in the form of a noise
pattern, a data structure 10820 comprising a plurality of noise
patterns and associated outcomes, and a machine learning data
analysis circuit 10812 structured to receive the output data 10810
and learn received output data patterns 10814 predictive of an
outcome or a state based on processing of the noise patterns.
[1074] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a plurality of sensors
selected among vibration sensors, ambient environment condition
sensors and local sensors for collecting non-vibration data
proximal to a machine in the environment, the plurality of sensors
communicatively coupled to a data collector; a data collection
circuit structured to collect output data from the plurality of
sensors; and a machine learning data analysis circuit structured to
receive the output data and learn received output data patterns
predictive of at least one of an outcome and a state. The state may
correspond to an outcome, anticipated outcome, outcome relating to
a process, as relating to a machine in the environment. The system
may be deployed on the data collector. The system may be
distributed between the data collector and a remote infrastructure.
The ambient environment condition sensors may include a noise
sensor, a temperature sensor, a flow sensor, a pressure sensor,
include a chemical sensor, a noise sensor, a temperature sensor, a
flow sensor, a pressure sensor, a chemical sensor, a vibration
sensor, an acceleration sensor, an accelerometer, a pressure
sensor, a force sensor, a position sensor, a location sensor, a
velocity sensor, a displacement sensor, a temperature sensor, a
thermographic sensor, a heat flux sensor, a tachometer sensor, a
motion sensor, a magnetic field sensor, an electrical field sensor,
a galvanic sensor, a current sensor, a flow sensor, a gaseous flow
sensor, a non-gaseous fluid flow sensor, a heat flow sensor, a
particulate flow sensor, a level sensor, a proximity sensor, a
toxic gas sensor, a chemical sensor, a CBRNE sensor, a pH sensor, a
hygrometer, a moisture sensor, a densitometer, an imaging sensor, a
camera, an SSR, a triax probe, an ultrasonic sensor, a touch
sensor, a microphone, a capacitive sensor, a strain gauge, and an
EMF meter. The local sensors may comprise one or more of a
vibration sensor, an acceleration sensor, an accelerometer, a
pressure sensor, a force sensor, a position sensor, a location
sensor, a velocity sensor, a displacement sensor, a temperature
sensor, a thermographic sensor, a heat flux sensor, a tachometer
sensor, a motion sensor, a magnetic field sensor, an electrical
field sensor, a galvanic sensor, a current sensor, a flow sensor, a
gaseous flow sensor, a non-gaseous fluid flow sensor, a heat flow
sensor, a particulate flow sensor, a level sensor, a proximity
sensor, a toxic gas sensor, a chemical sensor, a CBRNE sensor, a pH
sensor, a hygrometer, a moisture sensor, a densitometer, an imaging
sensor, a camera, an SSR, a triax probe, an ultrasonic sensor, a
touch sensor, a microphone, a capacitive sensor, a strain gauge,
and an EMF meter.
[1075] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collection circuit
structured to collect output data from a plurality of sensors
selected among vibration sensors, ambient environment condition
sensors and local sensors for collecting non-vibration data
proximal to a machine in the environment, the plurality of sensors
communicatively coupled to the data collection circuit; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns predictive of
at least one of an outcome and a state, wherein the monitoring
system is structured to determine if the output data matches a
learned received output data pattern. In embodiments, the machine
learning data analysis circuit may be structured to learn received
output data patterns by being seeded with a model, such as where
the model is a physical model, an operational model, or a system
model. The machine learning data analysis circuit may be structured
to learn received output data patterns based on the outcome or the
state. The monitoring system may keep or modify operational
parameters or equipment based on the predicted outcome or the
state. The data collection circuit collects data points from one or
more of the plurality of sensors based on the learned received
output data patterns, the outcome, or the state. The data
collection circuit may change a data storage technique for the
output data based on the learned received output data patterns, the
outcome, or the state. The data collection circuit may change a
data presentation mode or manner based on the learned received
output data patterns, the outcome, or the state. The data
collection circuit may apply one or more filters (low pass, high
pass, band pass, etc.) to the output data. The data collection
circuit may adjust the weights/biases of the machine learning data
analysis circuit, such as where the adjustment is in response to
the learned received output data patterns. The monitoring system
may remove, or re-task under-utilized equipment based on one or
more of the learned received output data patterns, the outcome, or
the state. The machine learning data analysis circuit may include a
neural network expert system. The machine learning data analysis
circuit may be structured to learn received output data patterns
indicative of progress/alignment with one or more goals or
guidelines, such as where progress or alignment of each goal or
guideline is determined by a different subset of the plurality of
sensors. The machine learning data analysis circuit may be
structured to learn received output data patterns indicative of an
unknown variable. The machine learning data analysis circuit may be
structured to learn received output data patterns indicative of a
preferred input sensor among available input sensors. The machine
learning data analysis circuit may be disposed in part on a
machine, on one or more data collectors, in network infrastructure,
in the cloud, or any combination thereof. The output data from the
vibration sensors may form a vibration fingerprint, such as where
the vibration fingerprint includes one or more of a frequency, a
spectrum, a velocity, a peak location, a wave peak shape, a
waveform shape, a wave envelope shape, an acceleration, a phase
information, and a phase shift. The data collection circuit may
apply a rule regarding how many parameters of the vibration
fingerprint to match or the standard deviation for the match in
order to identify a match between the output data and the learned
received output data pattern. The state may be one of a normal
operation, a maintenance required, a failure, or an imminent
failure. The monitoring system may trigger an alert based on the
predicted outcome or state. The monitoring system may shut down
equipment, component, or line based on the predicted outcome or
state. The monitoring system may initiate maintenance, lubrication,
or alignment based on the predicted outcome or state. The
monitoring system may deploy a field technician based on the
predicted outcome or state. The monitoring system may recommend a
vibration absorption or dampening device based on the predicted
outcome or state. The monitoring system may modify a process to
utilize backup equipment or a component based on the predicted
outcome or state. The monitoring system may modify a process to
preserve products or reactants based on the predicted outcome or
state. The monitoring system may generate or modify a maintenance
schedule based on the predicted outcome or state. The system may be
distributed between the data collector and a remote
infrastructure.
[1076] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collection circuit
structured to collect output data from a plurality of sensors
selected among vibration sensors, ambient environment condition
sensors and local sensors for collecting non-vibration data
proximal to a machine in the environment, the plurality of sensors
communicatively coupled to the data collection circuit; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns predictive of
at least one of an outcome and a state, wherein the monitoring
system is structured to determine if the output data matches a
learned received output data pattern and keep or modify operational
parameters or equipment based on the determination.
[1077] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collection circuit
structured to collect output data from a plurality of sensors
selected among vibration sensors, ambient environment condition
sensors and local sensors for collecting non-vibration data
proximal to a machine in the environment, the plurality of sensors
communicatively coupled to the data collection circuit; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns predictive of
at least one of an outcome and a state, wherein the output data
from the vibration sensors forms a vibration fingerprint. In
embodiments, the vibration fingerprint may comprise one or more of
a frequency, a spectrum, a velocity, a peak location, a wave peak
shape, a waveform shape, a wave envelope shape, an acceleration, a
phase information, and a phase shift. The data collection circuit
may apply a rule regarding how many parameters of the vibration
fingerprint to match or the standard deviation for the match in
order to identify a match between the output data and the learned
received output data pattern. The monitoring system may be
structured to determine if the output data matches a learned
received output data pattern and keep or modify operational
parameters or equipment based on the determination.
[1078] In embodiments, a monitoring system for data collection in
an industrial environment may comprise: a data collection band
circuit that identifies a subset of a plurality of sensors from
which to process output data, the sensors selected among vibration
sensors, ambient environment condition sensors and local sensors
for collecting non-vibration data proximal to a machine in the
environment, the plurality of sensors communicatively coupled to
the data collection band circuit; a data collection circuit
structured to collect the output data from the subset of plurality
of sensors; and a machine learning data analysis circuit structured
to receive the output data and learn received output data patterns
predictive of at least one of an outcome and a state wherein when
the learned received output data patterns do not reliably predict
the outcome or the state, the data collection band circuit alters
at least one parameter of at least one of the plurality of sensors.
In embodiments, the controller may identify a new data collection
band circuit based on one or more of the learned received output
data patterns and the outcome or state. The machine learning data
analysis circuit may be further structured to learn received output
data patterns indicative of a preferred input data collection band
among available input data collection bands. The system may be
distributed between the data collection circuit and a remote
infrastructure.
[1079] In embodiments, a monitoring system for data collection in
an industrial environment may comprise a data collection circuit
structured to collect output data from the plurality of sensors,
the sensors selected among vibration sensors, ambient environment
condition sensors and local sensors for collecting non-vibration
data proximal to a machine in the environment and being
communicatively coupled to the data collection circuit, wherein the
output data from the vibration sensors is in the form of a
vibration fingerprint; a data structure comprising a plurality of
vibration fingerprints and associated outcomes; and a machine
learning data analysis circuit structured to receive the output
data and learn received output data patterns predictive of an
outcome or a state based on processing of the vibration
fingerprints. The machine learning data analysis circuit may be
seeded with one of the plurality of vibration fingerprints from the
data structure. The data structure maybe updated if a changed
parameter resulted in a new vibration fingerprint or if a predicted
outcome did not occur in the absence of mitigation. The data
structure may be updated when the learned received output data
patterns do not reliably predict the outcome or the state. The
system may be distributed between the data collection circuit and a
remote infrastructure.
[1080] In embodiments, a monitoring system for data collection in
an industrial environment may comprise a data collection circuit
structured to collect output data from the plurality of sensors
selected among vibration sensors, ambient environment condition
sensors and local sensors for collecting non-vibration data
proximal to a machine in the environment, the plurality of sensors
communicatively coupled to the data collection circuit, wherein the
output data from the plurality of sensors is in the form of a noise
pattern; a data structure comprising a plurality of noise patterns
and associated outcomes; and a machine learning data analysis
circuit structured to receive the output data and learn received
output data patterns predictive of an outcome or a state based on
processing of the noise patterns.
[1081] An example system for data collection in an industrial
environment includes an industrial system having a number of
components, and a number of sensors wherein each of the sensors is
operatively coupled to at least one of the components. The example
system further includes a sensor communication circuit that
interprets a number of sensor data values in response to a sensed
parameter group, a pattern recognition circuit that determines a
recognized pattern value in response to a least a portion of the
sensor data values, and a sensor learning circuit that updates the
sensed parameter group in response to the recognized pattern value.
The example sensor communication circuit further adjusts the
interpreting the sensor data values in response to the updated
sensed parameter group.
[1082] Certain further aspects of an example system are described
following, any one or more of which may be present in certain
embodiments. An example system includes the sensed parameter group
being a fused number of sensors, and where the recognized pattern
value further includes a secondary value including a value
determined in response to the fused number of sensors. An example
system further includes the pattern recognition circuit and the
sensor learning circuit iteratively performing the determining the
recognized pattern value and the updating the sensed parameter
group to improve a sensing performance value. An example system
further includes the sensing performance value include a
determination of one or more of the following: a signal-to-noise
performance for detecting a value of interest in the industrial
system; a network utilization of the sensors in the industrial
system; an effective sensing resolution for a value of interest in
the industrial system; a power consumption value for a sensing
system in the industrial system, the sensing system including the
sensors; a calculation efficiency for determining the secondary
value; an accuracy and/or a precision of the secondary value; a
redundancy capacity for determining the secondary value; and/or a
lead time value for determining the secondary value. Example and
non-limiting calculation efficiency values include one or more
determinations such as: processor operations to determine the
secondary value; memory utilization for determining the secondary
value; a number of sensor inputs from the number of sensors for
determining the secondary value; and/or supporting data long-term
storage for supporting the secondary value.
[1083] An example system includes one or more, or all, of the
sensors as analog sensors and/or as remote sensors. An example
system includes the secondary value being a value such as: a
virtual sensor output value; a process prediction value; a process
state value; a component prediction value; a component state value;
and/or a model output value having the sensor data values from the
fused number of sensors as an input. An example system includes the
fused number of sensors being one or more of the combinations of
sensors such as: a vibration sensor and a temperature sensor; a
vibration sensor and a pressure sensor; a vibration sensor and an
electric field sensor; a vibration sensor and a heat flux sensor; a
vibration sensor and a galvanic sensor; and/or a vibration sensor
and a magnetic sensor.
[1084] An example sensor learning circuit further updates the
sensed parameter group by performing an operation such as: updating
a sensor selection of the sensed parameter group; updating a sensor
sampling rate of at least one sensor from the sensed parameter
group; updating a sensor resolution of at least one sensor from the
sensed parameter group; updating a storage value corresponding to
at least one sensor from the sensed parameter group; updating a
priority corresponding to at least one sensor from the sensed
parameter group; and/or updating at least one of a sampling rate,
sampling order, sampling phase, and/or a network path configuration
corresponding to at least one sensor from the sensed parameter
group. An example pattern recognition circuit further determines
the recognized pattern value by performing an operation such as:
determining a signal effectiveness of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to a value of interest; determining a sensitivity of at
least one sensor of the sensed parameter group and the updated
sensed parameter group relative to the value of interest;
determining a predictive confidence of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to the value of interest; determining a predictive delay
time of at least one sensor of the sensed parameter group and the
updated sensed parameter group relative to the value of interest;
determining a predictive accuracy of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to the value of interest; determining a predictive
precision of at least one sensor of the sensed parameter group and
the updated sensed parameter group relative to the value of
interest; and/or updating the recognized pattern value in response
to external feedback. Example and non-limiting values of interest
include: a virtual sensor output value; a process prediction value;
a process state value; a component prediction value; a component
state value; and/or a model output value having the sensor data
values from the fused plurality of sensors as an input.
[1085] An example pattern recognition circuit further accesses
cloud-based data including a second number of sensor data values,
the second number of sensor data values corresponding to at least
one offset industrial system. An example sensor learning circuit
further accesses the cloud-based data including a second updated
sensor parameter group corresponding to the at least one offset
industrial system.
[1086] An example procedure for data collection in an industrial
environment includes an operation to provide a number of sensors to
an industrial system including a number of components, each of the
number of sensors operatively coupled to at least one of the number
of components, an operation to interpret a number of sensor data
values in response to a sensed parameter group, the sensed
parameter group including a fused number of sensors from the number
of sensors, an operation to determine a recognized pattern value
including a secondary value determined in response to the number of
sensor data values, an operation to update the sensed parameter
group in response to the recognized pattern value, and an operation
to adjust the interpreting the number of sensor data values in
response to the updated sensed parameter group.
[1087] Certain further aspects of an example procedure are
described following, any one or more of which may be included in
certain embodiments. An example procedure includes an operation to
iteratively perform the determining the recognized pattern value
and the updating the sensed parameter group to improve a sensing
performance value, where determining the sensing performance value
includes an least one operation for determining a value, such as
determining: a signal-to-noise performance for detecting a value of
interest in the industrial system; a network utilization of the
plurality of sensors in the industrial system; an effective sensing
resolution for a value of interest in the industrial system; a
power consumption value for a sensing system in the industrial
system, the sensing system including the plurality of sensors; a
calculation efficiency for determining the secondary value; an
accuracy and/or a precision of the secondary value; a redundancy
capacity for determining the secondary value; and/or a lead time
value for determining the secondary value.
[1088] An example procedure includes an operation to update the
sensed parameter group comprised by performing at least one
operation such as: updating a sensor selection of the sensed
parameter group; updating a sensor sampling rate of at least one
sensor from the sensed parameter group; updating a sensor
resolution of at least one sensor from the sensed parameter group;
updating a storage value corresponding to at least one sensor from
the sensed parameter group; updating a priority corresponding to at
least one sensor from the sensed parameter group; and/or updating
at least one of a sampling rate, sampling order, sampling phase,
and a network path configuration corresponding to at least one
sensor from the sensed parameter group. An example procedure
includes determining the recognized pattern value by performing at
least one operation such as: determining a signal effectiveness of
at least one sensor of the sensed parameter group and the updated
sensed parameter group relative to a value of interest; determining
a sensitivity of at least one sensor of the sensed parameter group
and the updated sensed parameter group relative to the value of
interest; determining a predictive confidence of at least one
sensor of the sensed parameter group and the updated sensed
parameter group relative to the value of interest; determining a
predictive delay time of at least one sensor of the sensed
parameter group and the updated sensed parameter group relative to
the value of interest; determining a predictive accuracy of at
least one sensor of the sensed parameter group and the updated
sensed parameter group relative to the value of interest;
determining a predictive precision of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to the value of interest; and/or updating the recognized
pattern value in response to external feedback.
[1089] The term industrial system (and similar terms) as utilized
herein should be understood broadly. Without limitation to any
other aspect or description of the present disclosure, an
industrial system includes any large scale process system,
mechanical system, chemical system, assembly line, oil and gas
system (including, without limitation, production, transportation,
exploration, remote operations, offshore operations, and/or
refining), mining system (including, without limitation,
production, exploration, transportation, remote operations, and/or
underground operations), rail system (yards, trains, shipments,
etc.), construction, power generation, aerospace, agriculture, food
processing, and/or energy generation. Certain components may not be
considered industrial individually, but may be considered
industrially in an aggregated system--for example a single fan,
motor, and/or engine may be not an industrial system, but may be a
part of a larger system and/or be accumulated with a number of
other similar components to be considered an industrial system
and/or a part of an industrial system. In certain embodiments, a
system may be considered an industrial system for some purposes but
not for other purposes--for example a large data server farm may be
considered an industrial system for certain sensing operations,
such as temperature detection, vibration, or the like, but not an
industrial system for other sensing operations such as gas
composition. Additionally, in certain embodiments, otherwise
similar looking systems may be differentiated in determining
whether such system are industrial systems, and/or which type of
industrial system. For example, one data server farm may not, at a
given time, have process stream flow rates that are critical to
operation, while another data server farm may have process stream
flow rates that are critical to operation (e.g., a coolant flow
stream), and accordingly one data farm server may be an industrial
system for a data collection and/or sensing improvement process or
system, while the other is not. Accordingly, the benefits of the
present disclosure may be applied in a wide variety of systems, and
any such systems may be considered an industrial system herein,
while in certain embodiments a given system may not be considered
an industrial system herein. One of skill in the art, having the
benefit of the disclosure herein and knowledge about a contemplated
system ordinarily available to that person, can readily determine
which aspects of the present disclosure will benefit a particular
system, how to combine processes and systems from the present
disclosure to enhance operations of the contemplated system.
Certain considerations for the person of skill in the art, in
determining whether a contemplated system is an industrial system
and/or whether aspects of the present disclosure can benefit or
enhance the contemplated system include, without limitation: the
accessibility of portions of the system to positioning sensing
devices; the sensitivity of the system to capital costs (e.g.,
initial installation) and operating costs (e.g., optimization of
processes, reduction of power usage); the transmission environment
of the system (e.g., availability of broadband internet; satellite
coverage; wireless cellular access; the electro-magnetic ("EM")
environment of the system; the weather, temperature, and
environmental conditions of the system; the availability of
suitable locations to run wires, network lines, and the like; the
presence and/or availability of suitable locations for network
infrastructure, router positioning, and/or wireless repeaters); the
availability of trained personnel to interact with computing
devices; the desired spatial, time, and/or frequency resolution of
sensed parameters in the system; the degree to which a system or
process is well understood or modeled; the turndown ratio in system
operations (e.g., high load differential to low load; high flow
differential to low flow; high temperature operation differential
to low temperature operation); the turndown ratio in operating
costs (e.g., effects of personnel costs based on time (day, season,
etc.); effects of power consumption cost variance with time,
throughput, etc.); the sensitivity of the system to failure,
down-time, or the like; the remoteness of the contemplated system
(e.g., transport costs, time delays, etc.); and/or qualitative
scope of change in the system over the operating cycle (e.g., the
system runs several distinct processes requiring a variable sensing
environment with time; time cycle and nature of changes such as
periodic, event driven, lead times generally available, etc.).
While specific examples of industrial systems and considerations
are described herein for purposes of illustration, any system
benefitting from the disclosures herein, and any considerations
understood to one of skill in the art having the benefit of the
disclosures herein, are specifically contemplated within the scope
of the present disclosure.
[1090] The term sensor (and similar terms) as utilized herein
should be understood broadly. Without limitation to any other
aspect or description of the present disclosure, sensor includes
any device configured to provide a sensed value representative of a
physical value (e.g., temperature, force, pressure) in a system, or
representative of a conceptual value in a system at least having an
ancillary relationship to a physical value (e.g., work, state of
charge, frequency, phase, etc.).
[1091] Example and non-limiting sensors include vibration,
acceleration, noise, pressure, force, position, location, velocity,
displacement, temperature, heat flux, speed, rotational speed
(e.g., a tachometer), motion, accelerometers, magnetic field,
electrical field, galvanic, current, flow (gas, fluid, heat,
particulates, particles, etc.), level, proximity, gas composition,
fluid composition, toxicity, corrosiveness, acidity, pH, humidity,
hygrometer measures, moisture, density (bulk or specific),
ultrasound, imaging, analog, and/or digital sensors. The list of
sensed values is a non-limiting example, and the benefits of the
present disclosure in many applications can be realized independent
of the sensor type, while in other applications the benefits of the
present disclosure may be dependent upon the sensor type.
[1092] The sensor type and mechanism for detection may be any type
of sensor understood in the art. Without limitation, an
accelerometer may be any type and scaling, for example 500 mV per g
(1 g=9.8 m/s.sup.2), 100 mV, 1 V per g, 5 V per g, 10 V per g, 10
MV per g, as well as any frequency capability. It will be
understood for accelerometers, and for all sensor types, that the
scaling and range may be competing (e.g., in a fixed-bit or low bit
A/D system), and/or selection of high resolution scaling with a
large range may drive up sensor and/or computing costs, which may
be acceptable in certain embodiments, and may be prohibitive in
other embodiments. Example and non-limiting accelerometers include
piezo-electric devices, high resolution and sampling speed position
detection devices (e.g., laser based devices), and/or detection of
other parameters (strain, force, noise, etc.) that can be
correlated to acceleration and/or vibration. Example and
non-limiting proximity probes include electro-magnetic devices
(e.g., Hall effect, Variable Reluctance, etc.), a sleeve/oil film
device, and/or determination of other parameters than can be
correlated to proximity. An example vibration sensor includes a
tri-axial probe, which may have high frequency response (e.g.,
scaling of 100 MV/g). Example and non-limiting temperature sensors
include thermistors, thermocouples, and/or optical temperature
determination.
[1093] A sensor may, additionally or alternatively, provide a
processed value (e.g., a de-bounced, filtered, and/or compensated
value) and/or a raw value, with processing downstream (e.g., in a
data collector, controller, plant computer, and/or on a cloud-based
data receiver). In certain embodiments, a sensor provides a
voltage, current, data file (e.g., for images), or other raw data
output, and/or a sensor provides a value representative of the
intended sensed measurement (e.g., a temperature sensor may
communicate a voltage or a temperature value). Additionally or
alternatively, a sensor may communicate wirelessly, through a wired
connection, through an optical connection, or by any other
mechanism. The described examples of sensor types and/or
communication parameters are non-limiting examples for purposes of
illustration.
[1094] Additionally or alternatively, in certain embodiments, a
sensor is a distributed physical device--for example where two
separate sensing elements coordinate to provide a sensed value
(e.g., a position sensing element and a mass sensing element may
coordinate to provide an acceleration value). In certain
embodiments, a single physical device may form two or more sensors,
and/or parts of more than one sensor. For example, a position
sensing element may form a position sensor and a velocity sensor,
where the same physical hardware provides the sensed data for both
determinations.
[1095] The term smart sensor, smart device (and similar terms) as
utilized herein should be understood broadly. Without limitation to
any other aspect or description of the present disclosure, a smart
sensor includes any sensor and aspect thereof as described
throughout the present disclosure. A smart sensor includes an
increment of processing reflected in the sensed value communicated
by the sensor, including at least basic sensor processing (e.g.,
de-bouncing, filtering, compensation, normalization, and/or output
limiting), more complex compensations (e.g., correcting a
temperature value based on known effects of current environmental
conditions on the sensed temperature value, common mode or other
noise removal, etc.), a sensing device that provides the sensed
value as a network communication, and/or a sensing device that
aggregates a number of sensed values for communication (e.g.,
multiple sensors on a device communicated out in a parseable or
deconvolutable manner or as separate messages; multiple sensors
providing a value to a single smart sensor, which relays sensed
values on to a data collector, controller, plant computer, and/or
cloud-based data receiver). The use of the term smart sensor is for
purposes of illustration, and whether a sensor is a smart sensor
can depend upon the context and the contemplated system, and can be
a relative description compared to other sensors in the
contemplated system. Thus, a given sensor having identical
functionality may be a smart sensor for the purposes of one
contemplated system, and just a sensor for the purposes of another
contemplated system, and/or may be a smart sensor in a contemplated
system during certain operating conditions, and just a sensor for
the purposes of the same contemplated system during other operating
conditions.
[1096] The terms sensor fusion, fused sensors, and similar terms,
as utilized herein, should be understood broadly, except where
context indicates otherwise, without limitation to any other aspect
or description of the present disclosure. A sensor fusion includes
a determination of second order data from sensor data, and further
includes a determination of second order data from sensor data of
multiple sensors, including involving multiplexing of streams of
data, combinations of batches of data, and the like from the
multiple sensors. Second order data includes a determination about
a system or operating condition beyond that which is sensed
directly. For example, temperature, pressure, mixing rate, and
other data may be analyzed to determine which parameters are
result-effective on a desired outcome (e.g., a reaction rate). The
sensor fusion may include sensor data from multiple sources, and/or
longitudinal data (e.g., taken over a period of time, over the
course of a process, and/or over an extent of components in a
plant--for example tracking a number of assembled parts, a virtual
slug of fluid passing through a pipeline, or the like). The sensor
fusion may be performed in real-time (e.g., populating a number of
sensor fusion determinations with sensor data as a process
progresses), off-line (e.g., performed on a controller, plant
computer, and/or cloud-based computing device), and/or as a
post-processing operation (e.g., utilizing historical data, data
from multiple plants or processes, etc.). In certain embodiments, a
sensor fusion includes a machine pattern recognition operation--for
example where an outcome of a process is given to the machine
and/or determined by the machine, and the machine pattern
recognition operation determines result-effective parameters from
the detected sensor value space to determine which operating
conditions were likely to be the cause of the outcome and/or the
off-nominal result of the outcome (e.g., process was less effective
or more effective than nominal, failed, etc.). In certain
embodiments, the outcome may be a quantitative outcome (e.g., 20%
more product was produced than a nominal run) or a qualitative
outcome (e.g., product quality was unacceptable, component X of the
contemplated system failed during the process, component X of the
contemplated system required a maintenance or service event,
etc.).
[1097] In certain embodiments, a sensor fusion operation is
iterative or recursive--for example an estimated set of result
effective parameters is updated after the sensor fusion operation,
and a subsequent sensor fusion operation is performed on the same
data or another data set with an updated set of the result
effective parameters. In certain embodiments, subsequent sensor
fusion operations include adjustments to the sensing scheme--for
example higher resolution detections (e.g., in time, space, and/or
frequency domains), larger data sets (and consequent commitment of
computing and/or networking resources), changes in sensor
capability and/or settings (e.g., changing an A/D scaling, range,
resolution, etc.; changing to a more capable sensor and/or more
capable data collector, etc.) are performed for subsequent sensor
fusion operations. In certain embodiments, the sensor fusion
operation demonstrates improvements to the contemplated system
(e.g., production quantity, quality, and/or purity, etc.) such that
expenditure of additional resources to improve the sensing scheme
are justified. In certain embodiments, the sensor fusion operation
provides for improvement in the sensing scheme without incremental
cost--for example by narrowing the number of result effective
parameters and thereby freeing up system resources to provide
greater resolution, sampling rates, etc., from hardware already
present in the contemplated system. In certain embodiments,
iterative and/or recursive sensor fusion is performed on the same
data set, a subsequent data set, and/or a historical data set. For
example, high resolution data may already be present in the system,
and a first sensor fusion operation is performed with low
resolution data (e.g., sampled from the high resolution data set),
such as to allow for completion of sensor fusion processing
operations within a desired time frame, within a desired processor,
memory, and/or network utilization, and/or to allow for checking a
large number of variables as potential result effective parameters.
In a further example, a greater number of samples from the high
resolution data set may be utilized in a subsequent sensor fusion
operation in response to confidence that improvements are present,
narrowing of the potential result effective variables, and/or a
determination that higher resolution data is required to determine
the result effective parameters and/or effective values for such
parameters.
[1098] The described operations and aspects for sensor fusion are
non-limiting examples, and one of skill in the art, having the
benefit of the disclosures herein and information ordinarily
available about a contemplated system, can readily design a system
to utilize and/or benefit from a sensor fusion operation. Certain
considerations for a system to utilize and/or benefit from a sensor
fusion operation include, without limitation: the number of
components in the system; the cost of components in the system; the
cost of maintenance and/or down-time for the system; the value of
improvements in the system (production quantity, quality, yield,
etc.); the presence, possibility, and/or consequences of
undesirable system outcomes (e.g., side products, thermal and/or
luminary events, environmental benefits or consequences, hazards
present in the system); the expense of providing a multiplicity of
sensors for the system; the complexity between system inputs and
system outputs; the availability and cost of computing resources
(e.g., processing, memory, and/or communication throughput); the
size/scale of the contemplated system and/or the ability of such a
system to generate statistically significant data; whether offset
systems exist, including whether data from offset systems is
available and whether combining data from offset systems will
generate a statistically improved data set relative to the system
considered alone; and/or the cost of upgrading, improving, or
changing a sensing scheme for the contemplated system. The
described considerations for a contemplated system that may benefit
from or utilize a sensor fusion operation are non-limiting
illustrations.
[1099] Certain systems, processes, operations, and/or components
are described in the present disclosure as "offset systems" or the
like. An offset system is a system distinct from a contemplated
system, but having relevance to the contemplated system. For
example, a contemplated refinery may have an "offset refinery,"
which may be a refinery operated by a competitor, by a same entity
operating the contemplated refinery, and/or a historically operated
refinery that no longer exists. The offset refinery bears some
relevant relationship to the contemplated refinery, such as
utilizing similar reactions, process flows, production volumes,
feed stock, effluent materials, or the like. A system which is an
offset system for one purpose may not be an offset system for
another purpose. For example, a manufacturing process utilizing
conveyor belts and similar motors may be an offset process for a
contemplated manufacturing process for the purpose of tracking
product movement, understanding motor operations and failure modes,
or the like, but may not be an offset process for product quality
if the products being produced have distinct quality outcome
parameters. Any industrial system contemplated herein may have an
offset system for certain purposes. One of skill in the art, having
the benefit of the present disclosure and information ordinarily
available for a contemplated system, can readily determine what is
disclosed by an offset system or offset aspect of a system.
[1100] Any one or more of the terms computer, computing device,
processor, circuit, and/or server include a computer of any type,
capable to access instructions stored in communication thereto such
as upon a non-transient computer readable medium, whereupon the
computer performs operations of systems or methods described herein
upon executing the instructions. In certain embodiments, such
instructions themselves comprise a computer, computing device,
processor, circuit, and/or server. Additionally or alternatively, a
computer, computing device, processor, circuit, and/or server may
be a separate hardware device, one or more computing resources
distributed across hardware devices, and/or may include such
aspects as logical circuits, embedded circuits, sensors, actuators,
input and/or output devices, network and/or communication
resources, memory resources of any type, processing resources of
any type, and/or hardware devices configured to be responsive to
determined conditions to functionally execute one or more
operations of systems and methods herein.
[1101] Certain operations described herein include interpreting,
receiving, and/or determining one or more values, parameters,
inputs, data, or other information. Operations including
interpreting, receiving, and/or determining any value parameter,
input, data, and/or other information include, without limitation:
receiving data via a user input; receiving data over a network of
any type; reading a data value from a memory location in
communication with the receiving device; utilizing a default value
as a received data value; estimating, calculating, or deriving a
data value based on other information available to the receiving
device; and/or updating any of these in response to a later
received data value. In certain embodiments, a data value may be
received by a first operation, and later updated by a second
operation, as part of the receiving a data value. For example, when
communications are down, intermittent, or interrupted, a first
operation to interpret, receive, and/or determine a data value may
be performed, and when communications are restored an updated
operation to interpret, receive, and/or determine the data value
may be performed.
[1102] Certain logical groupings of operations herein, for example
methods or procedures of the current disclosure, are provided to
illustrate aspects of the present disclosure. Operations described
herein are schematically described and/or depicted, and operations
may be combined, divided, re-ordered, added, or removed in a manner
consistent with the disclosure herein. It is understood that the
context of an operational description may require an ordering for
one or more operations, and/or an order for one or more operations
may be explicitly disclosed, but the order of operations should be
understood broadly, where any equivalent grouping of operations to
provide an equivalent outcome of operations is specifically
contemplated herein. For example, if a value is used in one
operational step, the determining of the value may be required
before that operational step in certain contexts (e.g., where the
time delay of data for an operation to achieve a certain effect is
important), but may not be required before that operation step in
other contexts (e.g., where usage of the value from a previous
execution cycle of the operations would be sufficient for those
purposes). Accordingly, in certain embodiments an order of
operations and grouping of operations as described is explicitly
contemplated herein, and in certain embodiments re-ordering,
subdivision, and/or different grouping of operations is explicitly
contemplated herein.
[1103] Referencing FIG. 142, an example system 10902 for data
collection in an industrial environment includes an industrial
system 10904 having a number of components 10906, and a number of
sensors 10908, wherein each of the sensors 10908 is operatively
coupled to at least one of the components 10906. The selection,
distribution, type, and communicative setup of sensors depends upon
the application of the system 10902 and/or the context.
[1104] The example system 10902 further includes a sensor
communication circuit 10920 (reference FIG. 143) that interprets a
number of sensor data values 10948 in response to a sensed
parameter group 10928. The sensed parameter group 10928 includes a
description of which sensors 10908 are sampled at which times,
including at least the selected sampling frequency, a process stage
wherein a particular sensor may be providing a value of interest,
and the like. An example system includes the sensed parameter group
10928 being a fused number of sensors 10926, for example a set of
sensors believed to encompass detection of operating conditions of
the system that affect a desired output, such as production output,
quality, efficiency, profitability, purity, maintenance or service
predictions of components in the system, failure mode predictions,
and the like. In a further embodiment, the recognized pattern value
10930 further includes a secondary value 10932 including a value
determined in response to the fused number of sensors 10926.
[1105] In certain embodiments, sensor data values 10948 are
provided to a data collector 10910, which may be in communication
with multiple sensors 10908 and/or with a controller 10914. In
certain embodiments, a plant computer 10912 is additionally or
alternatively present. In the example system, the controller 10914
is structured to functionally execute operations of the sensor
communication circuit 10920, pattern recognition circuit 10922,
and/or the sensor learning circuit 10924, and is depicted as a
separate device for clarity of description. Aspects of the
controller 10914 may be present on the sensors 10908, the data
controller 10910, the plant computer 10912, and/or on a cloud
computing device 10916. In certain embodiments, all aspects of the
controller 10914 may be present in another device depicted on the
system 10902. The plant computer 10912 represents local computing
resources, for example processing, memory, and/or network
resources, that may be present and/or in communication with the
industrial system 10904. In certain embodiments, the cloud
computing device 10916 represents computing resources externally
available to the industrial system 10904, for example over a
private network, intra-net, through cellular communications,
satellite communications, and/or over the internet. In certain
embodiments, the data controller 10910 may be a computing device, a
smart sensor, a MUX box, or other data collection device capable to
receive data from multiple sensors and to pass-through the data
and/or store data for later transmission. An example data
controller 10910 has no storage and/or limited storage, and
selectively passes sensor data therethrough, with a subset of the
sensor data being communicated at a given time due to bandwidth
considerations of the data controller 10910, a related network,
and/or imposed by environmental constraints. In certain
embodiments, one or more sensors and/or computing devices in the
system 10902 are portable devices--for example a plant operator
walking through the industrial system may have a smart phone, which
the system 10902 may selectively utilize as a data controller
10910, sensor 10908--for example to enhance communication
throughput, sensor resolution, and/or as a primary method for
communicating sensor data values 10948 to the controller 10914.
[1106] The example system 10902 further includes a pattern
recognition circuit 10922 that determines a recognized pattern
value 10930 in response to a least a portion of the sensor data
values 10948.
[1107] The example system 10902 further includes a sensor learning
circuit 10924 that updates the sensed parameter group 10928 in
response to the recognized pattern value 10930. The example sensor
communication circuit 10920 further adjusts the interpreting the
sensor data values 10948 in response to the updated sensed
parameter group 10928.
[1108] An example system 10902 further includes the pattern
recognition circuit 10922 and the sensor learning circuit 10924
iteratively performing the determining the recognized pattern value
10930 and the updating the sensed parameter group 10928 to improve
a sensing performance value 10934. For example, the pattern
recognition circuit 10922 may add sensors, remove sensors, and/or
change sensor setting to modify the sensed parameter group 10928
based upon sensors which appear to be effective or ineffective
predictors of the recognized pattern value 10930, and the sensor
learning circuit 10924 may instruct a continued change (e.g., while
improvement is still occurring), an increased or decreased rate of
change (e.g., to converge more quickly on an improved sensed
parameter group 10928), and/or instruct a randomized change to the
sensed parameter group 10928 (e.g., to ensure that all potentially
result effective sensors are being checked, and/or to avoid
converging into a local optimal value).
[1109] Example and non-limiting options for the sensing performance
value 10934 include: a signal-to-noise performance for detecting a
value of interest in the industrial system (e.g., a determination
that the prediction signal for the value is high relative to noise
factors for one or more sensors of the sensed parameter group
10928, and/or for the sensed parameter group 10928 as a whole); a
network utilization of the sensors in the industrial system (e.g.,
the sensor learning circuit 10924 may score a sensed parameter
group 10928 relatively high where it is as effective or almost as
effective as another sensed parameter group 10928, but results in
lower network utilization); an effective sensing resolution for a
value of interest in the industrial system (e.g., the sensor
learning circuit 10924 may score a sensed parameter group 10928
relatively high where it provides a responsive prediction of the
output value to smaller changes in input values); a power
consumption value for a sensing system in the industrial system,
the sensing system including the sensors (e.g., the sensor learning
circuit 10924 may score a sensed parameter group 10928 relatively
high where it is as effective or almost as effective as another
sensed parameter group 10928, but results in lower power
consumption); a calculation efficiency for determining the
secondary value (e.g., the sensor learning circuit 10924 may score
a sensed parameter group 10928 relatively high where it is as
effective or almost as effective as another sensed parameter group
10928 in determining the secondary value 10932, but results in
fewer processor cycles, lower network utilization, and/or lower
memory utilization including stored memory requirements as well as
intermediate memory utilization such as buffers); an accuracy
and/or a precision of the secondary value (e.g., the sensor
learning circuit 10924 may score a sensed parameter group 10928
relatively high where it provides a highly accurate and/or highly
precise determination of the secondary value 10932); a redundancy
capacity for determining the secondary value (e.g., the sensor
learning circuit 10924 may score a sensed parameter group 10928
relatively high where it provides similar capability and/or
resource utilization, but provides for additional sensing
redundancy, such as being more robust to gaps in data from one or
more of the sensors in the sensed parameter group 10928); and/or a
lead time value for determining the secondary value 10932 (e.g.,
the sensor learning circuit 10924 may score a sensed parameter
group 10928 relatively high where it provides an improved or
sufficient lead time in the secondary value 10932
determination--for example to assist in avoiding over-temperature
operation, spoiling an entire production run, determining whether a
component has sufficient service life to complete a production run,
etc.) Example and non-limiting calculation efficiency values
include one or more determinations such as: processor operations to
determine the secondary value 10932; memory utilization for
determining the secondary value 10932; a number of sensor inputs
from the number of sensors for determining the secondary value
10932; and/or supporting memory, such as long-term storage or
buffers for supporting the secondary value 10932.
[1110] Example systems include one or more, or all, of the sensors
10908 as analog sensors and/or as remote sensors. An example system
includes the secondary value 10932 being a value such as: a virtual
sensor output value;
[1111] a process prediction value (e.g., a success value for a
production run, an overtemperature value, an overpressure value, a
product quality value, etc.); a process state value (e.g., a stage
of the process, a temperature at a time and location in the
process); a component prediction value (e.g., a component failure
prediction, a component maintenance or service prediction, a
component response to an operating change prediction); a component
state value (a remaining service life or maintenance interval for a
component); and/or a model output value having the sensor data
values 10948 from the fused number of sensors 10926 as an input. An
example system includes the fused number of sensors 10926 being one
or more of the combinations of sensors such as: a vibration sensor
and a temperature sensor; a vibration sensor and a pressure sensor;
a vibration sensor and an electric field sensor; a vibration sensor
and a heat flux sensor; a vibration sensor and a galvanic sensor;
and/or a vibration sensor and a magnetic sensor.
[1112] An example sensor learning circuit 10924 further updates the
sensed parameter group 10928 by performing an operation such as:
updating a sensor selection of the sensed parameter group 10928
(e.g., which sensors are sampled); updating a sensor sampling rate
of at least one sensor from the sensed parameter group (e.g., how
fast the sensors provide information, and/or how fast information
is passed through the network); updating a sensor resolution of at
least one sensor from the sensed parameter group (e.g., changing or
requesting a change in a sensor resolution, utilizing additional
sensors to provide greater effective resolution); updating a
storage value corresponding to at least one sensor from the sensed
parameter group (e.g., storing data from the sensor at a higher or
lower resolution, and/or over a longer or shorter time period);
updating a priority corresponding to at least one sensor from the
sensed parameter group (e.g., moving a sensor up to a higher
priority--for example, if environmental conditions prevent data
receipt from all planned sensors, and/or reducing a time lag
between creation of the sensed data and receipt at the sensor
learning circuit 10924); and/or updating at least one of a sampling
rate, sampling order, sampling phase, and/or a network path
configuration corresponding to at least one sensor from the sensed
parameter group.
[1113] An example pattern recognition circuit 10922 further
determines the recognized pattern value 10930 by performing an
operation such as: determining a signal effectiveness of at least
one sensor of the sensed parameter group and the updated sensed
parameter group relative to a value of interest 10950 (e.g.,
determining that a sensor value is a good predictor of the value of
interest 10950); determining a sensitivity of at least one sensor
of the sensed parameter group 10928 and the updated sensed
parameter group 10928 relative to the value of interest 10950
(e.g., determining the relative sensitivity of the determined value
of interest to small changes in operating conditions based on the
selected sensed parameter group 10928); determining a predictive
confidence of at least one sensor of the sensed parameter group
10928 and the updated sensed parameter group 10928 relative to the
value of interest 10950; determining a predictive delay time of at
least one sensor of the sensed parameter group 10928 and the
updated sensed parameter group 10928 relative to the value of
interest 10950; determining a predictive accuracy of at least one
sensor of the sensed parameter group 10928 and the updated sensed
parameter group 10928 relative to the value of interest 10950;
determining a classification precision of at least one sensor of
the sensed parameter group 10928 (e.g., determining the accuracy of
classification of a pattern by a machine classifier based on use of
the at least one sensor); determining a predictive precision of at
least one sensor of the sensed parameter group 10928 and the
updated sensed parameter group 10928 relative to the value of
interest 10950; and/or updating the recognized pattern value 10930
in response to external feedback, which may be received as external
data 10952 (e.g., where an outcome is known, such as a maintenance
event, product quality determination, production outcome
determination, etc., the detection of the recognized pattern value
10930 is thereby improved according to the conditions of the system
before the known outcome occurred). Example and non-limiting values
of interest 10950 include: a virtual sensor output value; a process
prediction value; a process state value; a component prediction
value; a component state value; and/or a model output value having
the sensor data values from the fused plurality of sensors as an
input.
[1114] An example pattern recognition circuit 10922 further
accesses cloud-based data 10954 including a second number of sensor
data values, the second number of sensor data values corresponding
to at least one offset industrial system. An example sensor
learning circuit 10924 further accesses the cloud-based data 10954
including a second updated sensor parameter group corresponding to
the at least one offset industrial system. Accordingly, the pattern
recognition circuit 10922 can improve pattern recognition in the
system based on increased statistical data available from an offset
system. Additionally, or alternatively, the sensor learning circuit
10924 can improve more rapidly and with greater confidence based
upon the data from the offset system--including determining which
sensors in the offset system found to be effective in predicting
system outcomes.
[1115] An example system includes an industrial system including an
oil refinery. An example oil refinery includes one or more
compressors for transferring fluids throughout the plant, and/or
for pressurizing fluid streams (e.g., for reflux in a distillation
column). Additionally, or alternatively, the example oil refinery
includes vacuum distillation, for example, to fractionate
hydrocarbons. The example oil refinery additionally includes
various pipelines in the system for transferring fluids, bringing
in feedstock, final product delivery, and the like. An example
system includes a number of sensors configured to determine each
aspect of a distillation column--for example temperatures of
various fluid streams, temperatures, and compositions of individual
contact trays in the column, measurements of the feed and reflux,
as well as of the effluent or separated products. The design of a
distillation column is complex, and optimal design can depend upon
the sizing of boilers, compressors, the contact conditions within
the column, as well as the composition of feedstock, all of which
can vary significantly. Additionally, the optimal position for
effective sensing of conditions in a pipeline can vary with fluid
flow rates, environmental conditions (e.g., causing variation in
heat transfer rates), the feedstock utilized, and other factors.
Additionally, wear or loss of capability in a boiler, compressor,
or other operating equipment can change the system response and
capabilities, rendering a single point optimization--including
where sensors should be positioned and how they should sample
data--to be non-optimal as the system ages.
[1116] Provision of multiple sensors throughout the system can be
costly, not necessarily because the sensors are expensive, but
because the sensors provide data which may be prohibitive to
transmit, store, and utilize. Cost may involve costs of
transmitting over networks, as well as costs of operations, such as
numbers of input/output operations (and time required to undertake
such operations). The example system includes providing a large
number of sensors throughout the system, and determining which of
the sensors are effective for control and optimization of the
distillation process. Additionally, as the feedstock and/or
environmental conditions change, the optimal sensor package for
both optimization and control may change. The example system
utilizes a pattern recognition circuit to determine which sensors,
including sensor fusion operations (including selection of groups,
selection of multiplexing and combination, and the like), are
effective in controlling the desired parameters of the
distillation, and in determining the optimal values for
temperatures, flow rates, entry trays for feed and reflux, and/or
reflux rates. Additionally, the sensor learning circuit is capable,
over time and/or utilizing offset oil refineries, to rapidly
converge on various sensor packages that are appropriate for a
multiplicity of operating conditions. If an unexpected operating
condition occurs--for example an off-nominal operation of a
compressor, the sensor learning circuit is capable of migrating the
system to the correct sensing and operating conditions for the
unexpected operating condition. The ability to flexibly utilize a
multiplicity of sensors allows for the system to be flexible in
response to changing conditions without providing for excessive
capability in transmission and storage of sensor data. Accordingly,
operations of the distillation column are improved and can be
optimized for a large number of operating conditions. Additionally,
alerts for the distillation column, based upon recognition of
patterns indicating off-nominal operation, can be readily prepared
to adjust or shut down the process before significant product
quality loss and/or hazardous conditions develop. Example sensor
fusion operations for a refinery include vibration information
combined with temperatures, pressures, and/or composition (e.g., to
determine compressor performance); temperature and pressure,
temperature and composition, and/or composition and pressure (e.g.,
to determine feedstock variance, contact tray performance, and/or a
component failure).
[1117] An example refinery system includes storage tanks and/or
boiler feed water. Example system determinations include a sensor
fusion to determine a storage tank failure and/or off-nominal
operation, such as through a temperature and pressure fusion,
and/or a vibration determination with a non-vibration determination
(e.g., detecting leaks, air in the system, and/or a feed pump
issue). Certain further example system determinations include a
sensor fusion to determine a boiler feed water failure, such as
through a sensor fusion including flow rate, pressure, temperature,
and/or vibration. Any one or more of these parameters can be
utilized to determine a system leak, failure, wear of a feed pump,
scaling, and/or to reduce pumping losses while maintaining system
flow rates. Similarly, an example industrial system includes a
power generation system having a condensate and/or make-up water
system, where a sensor fusion provides for a sensed parameter group
and prediction of failures, maintenance, and the like.
[1118] An example industrial system includes an irrigation system
for a field or a system of fields. Irrigations systems are subject
to significant variability in the system (e.g., inlet pressures
and/or water levels, component wear and maintenance) as well as
environmental variability (e.g., types and distribution of crops
planted, weather, soil moisture, humidity, seasonal variability in
the sun, cloud coverage, and/or wind variance). Additionally,
irrigation systems tend to be remotely located where high bandwidth
network access, maintenance facilities, and/or even personnel for
oversight are not readily available. An example system includes a
multiplicity of sensors capable of detecting conditions for the
irrigation system, without requiring that all of the sensors
transmit or store data on a continuous basis. The pattern
recognition circuit can readily determine the most important set of
sensors to effectively predict patterns and those system conditions
requiring a response (e.g., irrigation cycles, positioning, and the
like). The sensor learning circuit provides for responsive
migration of the sensed parameter group to variability, which may
occur on slower (e.g., seasonal, climate change, etc.) or faster
cycles (e.g., equipment failure, weather conditions, step change
events such as planting or harvesting). Additionally, alerts for
remote facilities can be readily prepared with confidence that the
correct sensor package is in place for determining an off-nominal
condition (e.g., imminent failure or maintenance requirement for a
pump).
[1119] An example industrial system includes a chemical or
pharmaceutical plant. Chemical plants require specific operating
conditions, flow rates, temperatures, and the like to maintain
proper temperatures, concentrations, mixing, and the like
throughout the system. In many systems, there are numerous process
steps, and an off-nominal or uncoordinated operation in one part of
the process can result in reduced yields, a failed process, and/or
a significant reduction in production capacity as coordinated
processes must respond (or as coordinated processes fail to
respond). Accordingly, a very large number of systems are required
to minimally define the system, and in certain embodiments a
prohibitive number of sensors are required, from a data
transmission and storage viewpoint, to keep sensing capability for
a broad range of operating conditions. Additionally, the complexity
of the system results in difficulty optimizing and coordinating
system operations even where sufficient sensors are present. In
certain embodiments, the pattern recognition circuit can determine
the sensing parameter groups that provide high resolution
understanding of the system, without requiring that all of the
sensors store and transmit data continuously. Further, the
utilization of a sensor fusion provides for the opportunity to
abstract desired outputs, for example "maximize yield" or "minimize
an undesirable side reaction" without requiring a full
understanding from the operator of which sensors and system
conditions are most effective to achieve the abstracted desired
output. Example components in a chemical or pharmaceutical plan
amenable to control and predictions based on a sensor fusion
operation include an agitator, a pressure reactor, a catalytic
reactor, and/or a thermic heating system. Example sensor fusion
operations to determine sensed parameter groups and tune the
pattern recognition circuit include, without limitation, a
vibration sensor combined with another sensor type, a composition
sensor combined with another sensor type, a flow rate determination
combined with another sensor type, and/or a temperature sensor
combined with another sensor type. The sensor fusion best suited
for a particular application can be converged upon by the sensor
learning circuit, but also depends upon the type of component that
is subject to predictions, as well as the type of desired outputs
pursued by the operator. For example, agitators are amenable to
vibration sensing, as well as uniformity of composition detection
(e.g., high resolution temperature), expected reaction rates in a
properly mixed system, and the like. Catalytic reactors are
amenable to temperature sensing (based on the reaction
thermodynamics), composition detection (e.g., for expected
reactants, as well as direct detection of catalytic material), flow
rates (e.g., gross mechanical failure, reduced volume of beads,
etc.), and/or pressure detection (e.g., indicative of or coupled
with flow rate changes).
[1120] An example industrial system includes a food processing
system. Example food processing systems include pressurization
vessels, stirrers, mixers, and/or thermic heating systems. Control
of the process is critical to maintain food safety, product
quality, and product consistency. However, most input parameters to
the food processing system are subject to high variability--for
example basic food products are inherently variable as natural
products, with differing water content, protein content, and
aesthetic variation. Additionally, labor cost management, power
cost management, and variability in supply water, etc., provide for
a complex process where determination of the process control
variables, sensed parameters to determine these, and optimization
of sensing in response to process variation are a difficult problem
to resolve. Food processing systems are often cost conscious, and
capital costs (e.g., for a robust network and computing system for
optimization) are not readily incurred. Further, a food processing
system may manufacture a wide variety of products on similar or the
same production facilities--for example, to support an entire
product line and/or due to seasonal variations. Accordingly, a
sensor setup for one process may not support another process well.
An example system includes the pattern recognition circuit
determining the sensing parameter groups that provide a strong
signal response in target outcomes even in light of high
variability in system conditions. The pattern recognition circuit
can provide for numerous sensed group parameter options available
for different process conditions without requiring extensive
computing or data storage resources. Additionally, the sensor
learning circuit provides for rapid response of the sensing system
to changes in the process conditions, including updating the sensed
group parameter options to pursue abstracted target outputs without
the operator having to understand which sensed parameters best
support the output goals. The sensor fusion best suited for a
particular application can be converged upon by the sensor learning
circuit, but also depends upon the type of component that is
subject to predictions, as well as the type of desired outputs
pursued by the operator. For example, control of and predictions
for pressurization vessels, stirrers, mixers, and/or thermic
heating systems are amenable to a sensor fusion with a temperature
determination combined with a non-temperature determination, a
vibration determination combined with a non-vibration
determination, and/or a heat map combined with a rate of change in
the heat map and/or a non-heat map determination. An example system
includes a sensor fusion with a vibration determination and a
non-vibration determination, wherein predictive information for a
mixer and/or a stirrer is provided. An example system includes a
sensor fusion with a pressure determination, a temperature
determination, and/or a non-pressure determination, wherein
predictive information for a pressurization vessel is provided.
[1121] Referencing FIG. 144, an example procedure 10936 for data
collection in an industrial environment includes an operation 10938
to provide a number of sensors to an industrial system including a
number of components, each of the number of sensors operatively
coupled to at least one of the number of components. The procedure
10936 further includes an operation 10940 to interpret a number of
sensor data values in response to a sensed parameter group, the
sensed parameter group including a fused number of sensors from the
number of sensors, an operation 10942 to determine a recognized
pattern value including a secondary value determined in response to
the number of sensor data values, an operation 10944 to update the
sensed parameter group in response to the recognized pattern value,
and an operation 10946 to adjust the interpreting the number of
sensor data values in response to the updated sensed parameter
group.
[1122] An example procedure 10936 includes an operation to
iteratively perform the determining the recognized pattern value
and the updating the sensed parameter group to improve a sensing
performance value (e.g., by repeating operations 10940 to 10944
periodically, at selected intervals, and/or in response to a system
change). An example procedure 10936 includes determining the
sensing performance value by determining: a signal-to-noise
performance for detecting a value of interest in the industrial
system; a network utilization of the plurality of sensors in the
industrial system; an effective sensing resolution for a value of
interest in the industrial system; a power consumption value for a
sensing system in the industrial system, the sensing system
including the plurality of sensors; a calculation efficiency for
determining the secondary value; an accuracy and/or a precision of
the secondary value; a redundancy capacity for determining the
secondary value; and/or a lead time value for determining the
secondary value.
[1123] An example procedure 10936 includes the operation 10944 to
update the sensed parameter group by performing at least one
operation such as: updating a sensor selection of the sensed
parameter group; updating a sensor sampling rate of at least one
sensor from the sensed parameter group; updating a sensor
resolution of at least one sensor from the sensed parameter group;
updating a storage value corresponding to at least one sensor from
the sensed parameter group; updating a priority corresponding to at
least one sensor from the sensed parameter group; and/or updating
at least one of a sampling rate, sampling order, sampling phase,
and a network path configuration corresponding to at least one
sensor from the sensed parameter group. An example procedure 10936
includes the operation 10942 to determine the recognized pattern
value by performing at least one operation such as: determining a
signal effectiveness of at least one sensor of the sensed parameter
group and the updated sensed parameter group relative to a value of
interest; determining a sensitivity of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to the value of interest; determining a predictive
confidence of at least one sensor of the sensed parameter group and
the updated sensed parameter group relative to the value of
interest; determining a predictive delay time of at least one
sensor of the sensed parameter group and the updated sensed
parameter group relative to the value of interest; determining a
predictive accuracy of at least one sensor of the sensed parameter
group and the updated sensed parameter group relative to the value
of interest; determining a predictive precision of at least one
sensor of the sensed parameter group and the updated sensed
parameter group relative to the value of interest; and/or updating
the recognized pattern value in response to external feedback.
[1124] Clause 1. In embodiments, a system for data collection in an
industrial environment, the system comprising: an industrial system
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; a sensor communication circuit structured to interpret
a plurality of sensor data values in response to a sensed parameter
group; a pattern recognition circuit structured to determine a
recognized pattern value in response to a least a portion of the
plurality of sensor data values; and a sensor learning circuit
structured to update the sensed parameter group in response to the
recognized pattern value; wherein the sensor communication circuit
is further structured to adjust the interpreting of the plurality
of sensor data values in response to the updated sensed parameter
group. 2. The system of clause 1, wherein the sensed parameter
group comprises a fused plurality of sensors, and wherein the
recognized pattern value further includes a secondary value
comprising a value determined in response to the fused plurality of
sensors. 3. The system of clause 2, wherein the pattern recognition
circuit and sensor learning circuit are further structured to
iteratively perform the determining the recognized pattern value
and the updating the sensed parameter group to improve a sensing
performance value. 4. The system of clause 3, wherein the sensing
performance value comprises at least one performance determination
selected from the performance determinations consisting of: a
signal-to-noise performance for detecting a value of interest in
the industrial system; a network utilization of the plurality of
sensors in the industrial system; an effective sensing resolution
for a value of interest in the industrial system; and a power
consumption value for a sensing system in the industrial system,
the sensing system including the plurality of sensors. 5. The
system of clause 3, wherein the sensing performance value comprises
a signal-to-noise performance for detecting a value of interest in
the industrial system. 6. The system of clause 3, wherein the
sensing performance value comprises a network utilization of the
plurality of sensors in the industrial system. 7. The system of
clause 3, wherein the sensing performance value comprises an
effective sensing resolution for a value of interest in the
industrial system. 8. The system of clause 3, wherein the sensing
performance value comprises a power consumption value for a sensing
system in the industrial system, the sensing system including the
plurality of sensors. 9. The system of clause 3, wherein the
sensing performance value comprises a calculation efficiency for
determining the secondary value. 10. The system of clause 9,
wherein the calculation efficiency comprises at least one of:
processor operations to determine the secondary value, memory
utilization for determining the secondary value, a number of sensor
inputs from the plurality of sensors for determining the secondary
value, and supporting data long-term storage for supporting the
secondary value. 11. The system of clause 3, wherein the sensing
performance value comprises one of an accuracy and a precision of
the secondary value. 12. The system of clause 3, wherein the
sensing performance value comprises a redundancy capacity for
determining the secondary value. 13. The system of clause 3,
wherein the sensing performance value comprises a lead time value
for determining the secondary value. 14. The system of clause 13,
wherein the secondary value comprises a component overtemperature
value. 15. The system of clause 13, wherein the secondary value
comprises one of a component maintenance time, a component failure
time, and a component service life. 16. The system of clause 13,
wherein the secondary value comprises an off nominal operating
condition affecting a product quality produced by an operation of
the industrial system. 17. The system of clause 1, wherein the
plurality of sensors comprises at least one analog sensor. 18. The
system of clause 1, wherein at least one of the sensors comprises a
remote sensor. 19. The system of clause 2, wherein the secondary
value comprises at least one value selected from the values
consisting of: a virtual sensor output value; a process prediction
value; a process state value; a component prediction value; a
component state value; and a model output value having the sensor
data values from the fused plurality of sensors as an input. 20.
The system of clause 2, wherein the fused plurality of sensors
further comprises at least one pairing of sensor types selected
from the pairings consisting of: a vibration sensor and a
temperature sensor; a vibration sensor and a pressure sensor; a
vibration sensor and an electric field sensor; a vibration sensor
and a heat flux sensor; a vibration sensor and a galvanic sensor;
and a vibration sensor and a magnetic sensor. 21. The system of
clause 1, wherein the sensor learning circuit is further structured
to update the sensed parameter group by performing at least one
operation selected from the operations consisting of: updating a
sensor selection of the sensed parameter group; updating a sensor
sampling rate of at least one sensor from the sensed parameter
group; updating a sensor resolution of at least one sensor from the
sensed parameter group; updating a storage value corresponding to
at least one sensor from the sensed parameter group; updating a
priority corresponding to at least one sensor from the sensed
parameter group; and updating at least one of a sampling rate,
sampling order, sampling phase, and a network path configuration
corresponding to at least one sensor from the sensed parameter
group. 22. The system of clause 21, wherein the pattern recognition
circuit is further structured to determine the recognized pattern
value by performing at least one operation selected from the
operations consisting of: determining a signal effectiveness of at
least one sensor of the sensed parameter group and the updated
sensed parameter group relative to a value of interest; determining
a sensitivity of at least one sensor of the sensed parameter group
and the updated sensed parameter group relative to the value of
interest; determining a predictive confidence of at least one
sensor of the sensed parameter group and the updated sensed
parameter group relative to the value of interest; determining a
predictive delay time of at least one sensor of the sensed
parameter group and the updated sensed parameter group relative to
the value of interest; determining a predictive accuracy of at
least one sensor of the sensed parameter group and the updated
sensed parameter group relative to the value of interest;
determining a predictive precision of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to the value of interest; and updating the recognized
pattern value in response to external feedback. 23. The system of
clause 22, wherein the value of interest comprises at least one
value selected from the values consisting of: a virtual sensor
output value; a process prediction value; a process state value; a
component prediction value; a component state value; and a model
output value having the sensor data values from the fused plurality
of sensors as an input. 24. The system of clause 2, wherein the
pattern recognition circuit is further structured to access
cloud-based data comprising a second plurality of sensor data
values, the second plurality of sensor data values corresponding to
at least one offset industrial system. 25. The system of clause 24,
wherein the sensor learning circuit is further structured to access
the cloud-based data comprising a second updated sensor parameter
group corresponding to the at least one offset industrial system.
26. A method, comprising: providing a plurality of sensors to an
industrial system comprising a plurality of components, each of the
plurality of sensors operatively coupled to at least one of the
plurality of components; interpreting a plurality of sensor data
values in response to a sensed parameter group, the sensed
parameter group comprising a fused plurality of sensors from the
plurality of sensors; determining a recognized pattern value
comprising a secondary value determined in response to the
plurality of sensor data values; updating the sensed parameter
group in response to the recognized pattern value; and adjusting
the interpreting the plurality of sensor data values in response to
the updated sensed parameter group. 27. The method of clause 26,
further comprising iteratively performing the determining the
recognized pattern value and the updating the sensed parameter
group to improve a sensing performance value. 28. The method of
clause 27, further comprising determining the sensing performance
value in response to determining at least one of: a signal-to-noise
performance for detecting a value of interest in the industrial
system; a network utilization of the plurality of sensors in the
industrial system;
[1125] an effective sensing resolution for a value of interest in
the industrial system; a power consumption value for a sensing
system in the industrial system, the sensing system including the
plurality of sensors; a calculation efficiency for determining the
secondary value, wherein the calculation efficiency comprises at
least one of: processor operations to determine the secondary
value, memory utilization for determining the secondary value, a
number of sensor inputs from the plurality of sensors for
determining the secondary value, and supporting data long-term
storage for supporting the secondary value; one of an accuracy and
a precision of the secondary value; a redundancy capacity for
determining the secondary value; and a lead time value for
determining the secondary value. 29. The method of clause 27,
wherein updating the sensed parameter group comprises performing at
least one operation selected from the operations consisting of:
updating a sensor selection of the sensed parameter group; updating
a sensor sampling rate of at least one sensor from the sensed
parameter group; updating a sensor resolution of at least one
sensor from the sensed parameter group; updating a storage value
corresponding to at least one sensor from the sensed parameter
group; updating a priority corresponding to at least one sensor
from the sensed parameter group; and updating at least one of a
sampling rate, sampling order, sampling phase, and a network path
configuration corresponding to at least one sensor from the sensed
parameter group. 30. The method of clause 27, wherein determining
the recognized pattern value comprises performing at least one
operation selected from the operations consisting of: determining a
signal effectiveness of at least one sensor of the sensed parameter
group and the updated sensed parameter group relative to a value of
interest; determining a sensitivity of at least one sensor of the
sensed parameter group and the updated sensed parameter group
relative to the value of interest; determining a predictive
confidence of at least one sensor of the sensed parameter group and
the updated sensed parameter group relative to the value of
interest; determining a predictive delay time of at least one
sensor of the sensed parameter group and the updated sensed
parameter group relative to the value of interest; determining a
predictive accuracy of at least one sensor of the sensed parameter
group and the updated sensed parameter group relative to the value
of interest; determining a predictive precision of at least one
sensor of the sensed parameter group and the updated sensed
parameter group relative to the value of interest; and updating the
recognized pattern value in response to external feedback. 31. A
system for data collection in an industrial environment, the system
comprising: an industrial system comprising a plurality of
components, and a plurality of sensors each operatively coupled to
at least one of the plurality of components; a sensor communication
circuit structured to interpret a plurality of sensor data values
in response to a sensed parameter group, wherein the sensed
parameter group comprises a fused plurality of sensors; a means for
recognizing a pattern value in response to the sensed parameter
group; and a means for updating the sensed parameter group in
response to the recognized pattern value. 32. The system of clause
31, further comprising a means for iteratively updating the sensed
parameter group. 33. The system of clause 32, further comprising a
means for accessing at least one of external data and a second
plurality of sensor data values corresponding to an offset
industrial system, and wherein the means for iteratively updating
the sensed parameter group is further responsive to the at least
one of external data and the second plurality of sensor data
values. 34. The system of clause 33, further comprising a means for
accessing a second sensed parameter group corresponding to the
offset industrial system, and wherein the means for iteratively
updating is further responsive to the second sensed parameter
group. 35. A system for data collection in an industrial
environment, the system comprising: an industrial system comprising
a plurality of components, and a plurality of sensors each
operatively coupled to at least one of the plurality of components;
a sensor communication circuit structured to interpret a plurality
of sensor data values in response to a sensed parameter group; a
pattern recognition circuit structured to determine a recognized
pattern value in response to a least a portion of the plurality of
sensor data values, wherein the recognized pattern value includes a
secondary value comprising a value determined in response to the at
least a portion of the plurality of sensors; a sensor learning
circuit structured to update the sensed parameter group in response
to the recognized pattern value; wherein the sensor communication
circuit is further structured to adjust the interpreting the
plurality of sensor data values in response to the updated sensed
parameter group; and wherein the pattern recognition circuit and
the sensor learning circuit are further structured to iteratively
perform the determining the recognized pattern value and the
updating the sensed parameter group to improve a sensing
performance value, wherein the sensing performance value comprises
a signal-to-noise performance for detecting a value of interest in
the industrial system. 36. The system of clause 35, wherein the
sensed parameter group comprises a fused plurality of sensors, and
wherein the secondary value comprises a value determined in
response to the fused plurality of sensors. 37. The system of
clause 36, wherein the secondary value comprises at least one value
selected from the values consisting of: a virtual sensor output
value; a process prediction value; a process state value; a
component prediction value; a component state value; and a model
output value having the sensor data values from the fused plurality
of sensors as an input. 38. A system for data collection in an
industrial environment, the system comprising: an industrial system
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; a sensor communication circuit structured to interpret
a plurality of sensor data values in response to a sensed parameter
group; a pattern recognition circuit structured to determine a
recognized pattern value in response to a least a portion of the
plurality of sensor data values, wherein the recognized pattern
value includes a secondary value comprising a value determined in
response to the at least a portion of the plurality of sensors; a
sensor learning circuit structured to update the sensed parameter
group in response to the recognized pattern value; wherein the
sensor communication circuit is further structured to adjust the
interpreting the plurality of sensor data values in response to the
updated sensed parameter group; and wherein the pattern recognition
circuit and the sensor learning circuit are further structured to
iteratively perform the determining the recognized pattern value
and the updating the sensed parameter group to improve a sensing
performance value, wherein the sensing performance value comprises
a network utilization of the plurality of sensors in the industrial
system. 39. The system of clause 37, wherein the sensed parameter
group comprises a fused plurality of sensors, and wherein the
secondary value comprises a value determined in response to the
fused plurality of sensors. 40. The system of clause 39, wherein
the secondary value comprises at least one value selected from the
values consisting of: a virtual sensor output value; a process
prediction value; a process state value; a component prediction
value; a component state value; and a model output value having the
sensor data values from the fused plurality of sensors as an input.
41. A system for data collection in an industrial environment, the
system comprising: an industrial system comprising a plurality of
components, and a plurality of sensors each operatively coupled to
at least one of the plurality of components; a sensor communication
circuit structured to interpret a plurality of sensor data values
in response to a sensed parameter group; a pattern recognition
circuit structured to determine a recognized pattern value in
response to a least a portion of the plurality of sensor data
values, wherein the recognized pattern value includes a secondary
value comprising a value determined in response to the at least a
portion of the plurality of sensors; a sensor learning circuit
structured to update the sensed parameter group in response to the
recognized pattern value; wherein the sensor communication circuit
is further structured to adjust the interpreting the plurality of
sensor data values in response to the updated sensed parameter
group; and wherein the pattern recognition circuit and the sensor
learning circuit are further structured to iteratively perform the
determining the recognized pattern value and the updating the
sensed parameter group to improve a sensing performance value,
wherein the sensing performance value comprises an effective
sensing resolution for a value of interest in the industrial
system. 42. The system of clause 41, wherein the sensed parameter
group comprises a fused plurality of sensors, and wherein the
secondary value comprises a value determined in response to the
fused plurality of sensors. 43. The system of clause 42, wherein
the secondary value comprises at least one value selected from the
values consisting of: a virtual sensor output value; a process
prediction value; a process state value; a component prediction
value; a component state value; and a model output value having the
sensor data values from the fused plurality of sensors as an input.
44. A system for data collection in an industrial environment, the
system comprising: an industrial system comprising a plurality of
components, and a plurality of sensors each operatively coupled to
at least one of the plurality of components; a sensor communication
circuit structured to interpret a plurality of sensor data values
in response to a sensed parameter group; a pattern recognition
circuit structured to determine a recognized pattern value in
response to a least a portion of the plurality of sensor data
values, wherein the recognized pattern value includes a secondary
value comprising a value determined in response to the at least a
portion of the plurality of sensors; a sensor learning circuit
structured to update the sensed parameter group in response to the
recognized pattern value; wherein the sensor communication circuit
is further structured to adjust the interpreting the plurality of
sensor data values in response to the updated sensed parameter
group; and wherein the pattern recognition circuit and the sensor
learning circuit are further structured to iteratively perform the
determining the recognized pattern value and the updating the
sensed parameter group to improve a sensing performance value,
wherein the sensing performance value comprises a power consumption
value for a sensing system in the industrial system, the sensing
system including the plurality of sensors. 45. The system of clause
44, wherein the sensed parameter group comprises a fused plurality
of sensors, and wherein the secondary value comprises a value
determined in response to the fused plurality of sensors. 46. The
system of clause 45, wherein the secondary value comprises at least
one value selected from the values consisting of: a virtual sensor
output value; a process prediction value; a process state value; a
component prediction value; a component state value; and a model
output value having the sensor data values from the fused plurality
of sensors as an input.
[1126] Referencing FIG. 145, an example system 11000 for data
collection in an industrial environment includes an industrial
system 11002 having a number of components 11004, and a number of
sensors 11006 each operatively coupled to at least one of the
number of components 11004. The selection, distribution, type, and
communicative setup of sensors depends upon the application of the
system 11000 and/or the context.
[1127] The example system 11000 further includes a sensor
communication circuit 11018 (reference FIG. 146) that interprets a
number of sensor data values 11034 in response to a sensed
parameter group 11026. The sensed parameter group 11026 includes a
description of which sensors 11006 are sampled at which times,
including at least the selected sampling frequency, a process stage
wherein a particular sensor may be providing a value of interest,
and the like. An example system includes the sensed parameter group
11026 being a number of sensors provided for a sensor fusion
operation. In certain embodiments, the sensed parameter group 11026
includes a set of sensors that encompass detection of operating
conditions of the system that predict outcomes, off-nominal
operations, maintenance intervals, maintenance health states,
and/or future state values for any of these, for a process, a
component, a sensor, and/or any aspect of interest for the system
11000.
[1128] In certain embodiments, sensor data values 11034 are
provided to a data collector 11008, which may be in communication
with multiple sensors 11006 and/or with a controller 11012. In
certain embodiments, a plant computer 11010 is additionally or
alternatively present. In the example system, the controller 11012
is structured to functionally execute operations of the sensor
communication circuit 11018, pattern recognition circuit 11020,
and/or the system characterization circuit 11022, and is depicted
as a separate device for clarity of description. Aspects of the
controller 11012 may be present on the sensors 11006, the data
collector 11008, the plant computer 11010, and/or on a cloud
computing device 11014. In certain embodiments, all aspects of the
controller 11012 may be present in another device depicted on the
system 11000. The plant computer 11010 represents local computing
resources, for example processing, memory, and/or network
resources, that may be present and/or in communication with the
industrial system 11000. In certain embodiments, the cloud
computing device 11014 represents computing resources externally
available to the industrial system 11000, for example over a
private network, intra-net, through cellular communications,
satellite communications, and/or over the internet. In certain
embodiments, the data collector 11008 may be a computing device, a
smart sensor, a MUX box, or other data collection device capable to
receive data from multiple sensors and to pass-through the data
and/or store data for later transmission. An example data collector
11008 has no storage and/or limited storage, and selectively passes
sensor data therethrough, with a subset of the sensor data being
communicated at a given time due to bandwidth considerations of the
data collector 11008, a related network, and/or imposed by
environmental constraints. In certain embodiments, one or more
sensors and/or computing devices in the system 11000 are portable
devices--for example a plant operator walking through the
industrial system may have a smart phone, which the system 11000
may selectively utilize as a data collector 11008, sensor
11006--for example to enhance communication throughput, sensor
resolution, and/or as a primary method for communicating sensor
data values 11034 to the controller 11012.
[1129] The example system 11000 further includes a pattern
recognition circuit 11020 that determines a recognized pattern
value 11028 in response to a least a portion of the sensor data
values 11034, and a system characterization circuit 11022 that
provides a system characterization value 11030 for the industrial
system in response to the recognized pattern value 11028. The
system characterization value 11030 includes any value determined
from the pattern recognition operations of the pattern recognition
circuit 11020, including determining that a system condition of
interest is present, a component condition of interest is present,
an abstracted condition of the system or a component is present
(e.g., a product quality value; an operation cost value; a
component health, wear, or maintenance value; a component capacity
value; and/or a sensor saturation value) and/or is predicted to
occur within a time frame (e.g., calendar time, operational time,
and/or a process stage) of interest. Pattern recognition operations
include determining that operations compatible with a previously
known pattern, operations similar to a previously known pattern
and/or extrapolated from previously known pattern information
(e.g., a previously known pattern includes a temperature response
for a first component, and a known or estimated relationship
between components allows for a determination that a temperature
for a second component will exceed a threshold based upon the
pattern recognition for the first component combined with the known
or estimated relationship).
[1130] Non-limiting descriptions of a number of examples of a
system characterization value 11030 are described following. An
example system characterization value 11030 includes a predicted
outcome for a process associated with the industrial system--for
example a product quality description, a product quantity
description, a product variability description (e.g., the expected
variability of a product parameter predicted according to the
operating conditions of the system), a product yield description, a
net present value (NPV) for a process, a process completion time, a
process chance of completion success, and/or a product purity
result. The predicted outcome may be a batch prediction (e.g., a
single run, or an integer number of runs, of the process, and the
associated predicted outcome), a time based prediction (e.g., the
projected outcome of the process over the next day, the next three
weeks, until a scheduled shutdown, etc.), a production defined
prediction (e.g., the projected outcome over the next 1,000 units,
over the next 47 orders, etc.), and/or a rate of change based
outcome (e.g., projected for 3 component failures per month, an
emissions output per year, etc.). An example system
characterization value 11030 includes a predicted future state for
a process associated with the industrial system--for example an
operating temperature at a given future time, an energy consumption
value, a volume in a tank, an emitted noise value at a school
adjacent to the industrial system, and/or a rotational speed of a
pump. The predicted future state may be time based (e.g., at 4 PM
on Thursday), based on a state of the process (e.g., during the
third stage, during system shutdown, etc.), and/or based on a
future state of particular interest (e.g., peak energy consumption,
highest temperature value, maximum noise value, time or process
stage when a maximum number of personnel will be within 50 feet of
a sensitive area, time or process stage when an aspect of the
system redundancy is at a lowest point--e.g., for determining high
risk points in a process, etc.). An example system characterization
value 11030 includes a predicted off-nominal operation for the
process associated with the industrial system--for example when a
component capacity of the system will exceed nominal parameters
(although, possibly, not experience a failure), when any parameter
in the system will be three standard deviations away from normal
operations, when a capacity of a component will be under-utilized,
etc. An example system characterization value 11030 includes a
prediction value for one of the number of components--for example
an operating condition at a point in time and/or process stage. An
example system characterization value 11030 includes a future state
value for one of the number of components. The predicted future
state of a component may be time based, based on a state of the
process, and/or based on a future state of particular interest
(e.g., a highest or lowest value predicted for the component). An
example system characterization value 11030 includes an anticipated
maintenance health state information for one of the number of
components, including at a particular time, a process stage, a
lowest value predicted until a next maintenance event, etc. An
example system characterization value 11030 includes a predicted
maintenance interval for at least one of the number of components
(e.g., based on current usage, anticipated usage, planned process
operations, etc.). An example system characterization value 11030
includes a predicted off-nominal operation for one of the number of
components--for example at a selected time, a process stage, and/or
a future state of particular interest. An example system
characterization value 11030 includes a predicted fault operation
for one of the plurality of components--for example at a selected
time, a process stage, any fault occurrence predicted based on
current usage, anticipated usage, planned process operations,
and/or a future state of particular interest. An example system
characterization value 11030 includes a predicted exceedance value
for one of the number of components, where the exceedance value
includes exceedance of a design specification, and/or exceedance of
a selected threshold. An example system characterization value
11030 includes a predicted saturation value for one of the
plurality of sensors for example at a selected time, a process
stage, any saturation occurrence predicted based on current usage,
anticipated usage, planned process operations, and/or a future
state of particular interest.
[1131] Any values for the prediction value 11030 may be raw values
(e.g., a temperature value), derivative values (e.g., a rate of
change of a temperature value), accumulated values (e.g., a time
spent above one or more temperature thresholds) including weighted
accumulated values, and/or integrated values (e.g., an area over a
temperature-time curve at a temperature value or temperature
trajectory of interest). The provided examples list temperature,
but any prediction value 11030 may be utilized, including at least
vibration, system throughput, pressure, etc. In certain
embodiments, combinations of one or more prediction values 11030
may be utilized.
[1132] It will be appreciated in light of the disclosure that
combining prediction values 11030 can create particularly powerful
combinations for system analysis, control, and risk management,
which are specifically contemplated herein. For example, a first
prediction value may indicate a time or process stage for a maximum
flow rate through the system, and a second prediction value may
determine the predicted state of one or more components of the
system that is present at that particular time or process stage. In
another example, a first prediction value indicates a lowest margin
of the system in terms of capacity to deliver (e.g., by determining
a point in the process wherein at least one component has a lowest
operating margin, and/or where a group of components have a
statistically lower operating margin due to the risk induced by a
number of simultaneous low operating margins), and a second
prediction value testing a system risk (e.g., loss of inlet water,
loss of power, increase in temperature, change in environmental
conditions that reduce or increase heat transfer, or that preclude
the emission of certain effluents), and the combined risk of
separate events can be assessed on the total system risk.
Additionally, the prediction values may be operated with a
sensitivity check (e.g., varying system conditions within margins
to determine if some failure may occur), wherein the use of the
prediction value allows for the sensitivity check to be performed
with higher resolution at high risk points in the process.
[1133] An example system 11000 further includes a system
collaboration circuit 11024 that interprets external data 11036,
and where the pattern recognition circuit 11020 further determines
the recognized pattern value 11028 further in response to the
external data 11036. External data 11036 includes, without
limitation, data provided from outside the system 11000 and/or
outside the controller 11012. Non-limiting example external data
11036 include entries from an operator (e.g., indicating a failure,
a fault, and/or a service event). An example pattern recognition
circuit 11020 further iteratively improves pattern recognition
operations in response to the external data 11036 (e.g., where an
outcome is known, such as a maintenance event, product quality
determination, production outcome determination, etc., the
detection of the recognized pattern value 11028 is thereby improved
according to the conditions of the system before the known outcome
occurred). Example and non-limiting external data 11036 includes
data such as: an indicated process success value; an indicated
process failure value; an indicated component maintenance event; an
indicated component failure event; an indicated process outcome
value; an indicated component wear value; an indicated process
operational exceedance value; an indicated component operational
exceedance value; an indicated fault value; and/or an indicated
sensor saturation value.
[1134] An example system 11000 further includes a system
collaboration circuit 11024 that interprets cloud-based data 11032
including a second number of sensor data values, the second number
of sensor data values corresponding to at least one offset
industrial system, and where the pattern recognition circuit 11020
further determines the recognized pattern value 11028 further in
response to the cloud-based data 11032. An example pattern
recognition circuit 11020 further iteratively improves pattern
recognition operations in response to the cloud-based data 11032.
An example sensed parameter group 11026 includes a triaxial
vibration sensor, a vibration sensor and a second sensor that is
not a vibration sensor, the second sensor being a digital sensor,
and/or a number of analog sensors.
[1135] An example system includes an industrial system including an
oil refinery. An example oil refinery includes one or more
compressors for transferring fluids throughout the plant, and/or
for pressurizing fluid streams (e.g., for reflux in a distillation
column). Additionally, or alternatively, the example oil refinery
includes vacuum distillation, for example to fractionate
hydrocarbons. The example oil refinery additionally includes
various pipelines in the system for transferring fluids, bringing
in feedstock, final product delivery, and the like. An example
system includes a number of sensors configured to determine each
aspect of a distillation column--for example temperatures of
various fluid streams, temperatures, and compositions of individual
contact trays in the column, measurements of the feed and reflux,
as well as of the effluent or separated products. The design of a
distillation column is complex, and optimal design can depend upon
the sizing of boilers, compressors, the contact conditions within
the column, as well as the composition of feedstock, which can vary
significantly. Additionally, the optimal position for effective
sensing of conditions in a pipeline can vary with fluid flow rates,
environmental conditions (e.g., causing variation in heat transfer
rates), the feedstock utilized, and other factors. Additionally,
wear or loss of capability in a boiler, compressor, or other
operating equipment can change the system response and
capabilities, rendering a single point optimization, including
where sensors should be positioned and how they should sample data,
to be non-optimal as the system ages.
[1136] Provision of multiple sensors throughout the system can be
costly, not necessarily because the sensors are expensive, but
because the sensors provide data that may be prohibitive to
transmit, store, and utilize. The example system includes providing
a large number of sensors throughout the system, and predicting the
future states of components, process variables, products, and/or
emissions for the system. The example system utilizes a pattern
recognition circuit to determine not only the future predicted
state of parameters, but when the future predicted state of
parameters will be of interest, and/or will combine with other
future predicted state of parameters to create additional risks or
opportunities.
[1137] Additionally, the system characterization circuit and the
system collaboration circuit can improve predictions and/or system
characterizations over time, and/or utilizing offset oil
refineries, to more robustly make predictions or system
characterizations, which can provide for earlier detection, longer
term planning for overall enterprise optimization, and/or to allow
the industrial system to operate closer to margins. If an
unexpected operating condition occurs--for example an off-nominal
operation of a compressor, the sensor collaboration circuit is able
to migrate the system prediction and improve the capability to
detect the conditions that caused the unexpected operating
condition in the system, and/or in offset systems. Additionally,
alerts for the distillation column, based upon predictions
indicating off-nominal operation, marginal operation, high risk
operation, and/or upcoming maintenance or potential failures, can
be readily prepared to provide visibility to risks that otherwise
may not be apparent by simply looking at system capacities and past
experience without rigorous analysis.
[1138] Example sensor fusion operations for a refinery include
vibration information combined with temperatures, pressures, and/or
composition (e.g., to determine compressor performance);
temperature and pressure, temperature and composition, and/or
composition, and pressure (e.g., to determine feedstock variance,
contact tray performance, and/or a component failure).
[1139] An example refinery system includes storage tanks and/or
boiler feed water. Example system determinations include a sensor
fusion to determine a storage tank failure and/or off-nominal
operation, such as through a temperature and pressure fusion,
and/or a vibration determination with a non-vibration determination
(e.g., detecting leaks, air in the system, and/or a feed pump
issue). Certain further example system predictions include a sensor
fusion to determine a boiler feed water failure, such as through a
sensor fusion including flow rate, pressure, temperature, and/or
vibration. Any one or more of these parameters can be utilized to
predict a system leak, failure, wear of a feed pump, and/or
scaling.
[1140] Similarly, an example industrial system includes a power
generation system having a condensate and/or make-up water system,
where a sensor fusion provides for a sensed parameter group and
prediction of failures, maintenance, and the like. The system
characterization circuit, utilizing sensor fusion and/or a
continuous machine learning process, can predict failures,
off-nominal operations, component health, and/or maintenance events
for, without limitation, compressors, piping, storage tanks, and/or
boiler feed water for an oil refinery.
[1141] An example industrial system includes an irrigation system
for a field or a system of fields. Irrigations systems are subject
to significant variability in the system (e.g., inlet pressures
and/or water levels, component wear and maintenance) as well as
environmental variability (e.g., types and distribution of crops
planted, weather, soil moisture, humidity, seasonal variability in
the sun, cloud coverage, and/or wind variance). Additionally,
irrigation systems tend to be remotely located where high bandwidth
network access, maintenance facilities, and/or even personnel for
oversight are not readily available. An example system includes a
multiplicity of sensors capable to enable prediction of conditions
for the irrigation system, without requiring that all of the
sensors transmit or store data on a continuous basis. The pattern
recognition circuit can readily determine the most important set of
sensors to effectively predict patterns and thus system conditions
requiring a response (e.g., irrigation cycles, positioning, and the
like). Additionally, alerts for remote facilities can be readily
prepared, with confidence that the correct sensor package is in
place for predicting an off-nominal condition (e.g., imminent
failure or maintenance requirement for a pump). In certain
embodiments, the system may determine an off-nominal process
condition such as water feed availability being below normal (e.g.,
based upon recognized pattern conditions such as recent
precipitation history, water production history from the irrigation
system or other systems competing for the same water feed),
structured news alerts or external data, etc., and update the
sensed parameter group, for example to confirm the water feed
availability (e.g., a water level sensor in a relevant location),
to confirm that acceptable conditions are available that water
delivery levels can be dropped (e.g., a humidity sensor, and/or a
prompt to a user), and/or to confirm that sufficient available
secondary sources are available (e.g., an auxiliary water level
sensor).
[1142] An example industrial system includes a chemical or
pharmaceutical plant. Chemical plants require specific operating
conditions, flow rates, temperatures, and the like to maintain
proper temperatures, concentrations, mixing, and the like
throughout the system. In many systems, there are numerous process
steps, and an off-nominal or uncoordinated operation in one part of
the process can result in reduced yields, a failed process, and/or
a significant reduction in production capacity as coordinated
processes must respond (or as coordinated processes fail to
respond). Accordingly, a very large number of systems are required
to minimally define the system, and in certain embodiments a
prohibitive number of sensors are required, from a data
transmission and storage viewpoint, to keep sensing capability for
a broad range of operating conditions. Additionally, the complexity
of the system results in difficulty optimizing and coordinating
system operations even where sufficient sensors are present. In
certain embodiments, the pattern recognition circuit can predict
the sensing parameter groups that provide high resolution
understanding of the system, without requiring that all of the
sensors store and transmit data continuously. Further, the pattern
recognition circuit can highlight the predicted system risks and
capacity limitations for upcoming process operations, where the
risks are buried in the complex process. Accordingly, this means it
can confidently be operated closer to margins, at a lower cost,
and/or maintenance or system upgrades can be performed before
failures or capacity limitations are experienced.
[1143] Further, the utilization of a sensor fusion provides for the
opportunity to abstract desired predictions, such as "maximize
quality" or "minimize and undesirable side reaction" without
requiring a full understanding from the operator of which sensors
and system conditions are most effective to achieve the abstracted
desired output. Further, the predictive nature of the pattern
recognition circuit allows for changes in the process to support
the desired outcome to be implemented before the process is
committed to a sub-optimal outcome. Example components in a
chemical or pharmaceutical plan amenable to control and predictions
based on operations of the pattern recognition circuit and/or a
sensor fusion operation include an agitator, a pressure reactor, a
catalytic reactor, and/or a thermic heating system. Example sensor
fusion operations to determine sensed parameter groups and tune the
pattern recognition circuit include, without limitation, a
vibration sensor combined with another sensor type, a composition
sensor combined with another sensor type, a flow rate determination
combined with another sensor type, and/or a temperature sensor
combined with another sensor type. For example, agitators are
amenable to vibration sensing, as well as uniformity of composition
detection (e.g., high resolution temperature), expected reaction
rates in a properly mixed system, and the like. Catalytic reactors
are amenable to temperature sensing (based on the reaction
thermodynamics), composition detection (e.g., for expected
reactants, as well as direct detection of catalytic material), flow
rates (e.g., gross mechanical failure, reduced volume of beads,
etc.), and/or pressure detection (e.g., indicative of or coupled
with flow rate changes).
[1144] An example industrial system includes a food processing
system. Example food processing systems include pressurization
vessels, stirrers, mixers, and/or thermic heating systems. Control
of the process is critical to maintain food safety, product
quality, and product consistency. However, most input parameters to
the food processing system are subject to high variability--for
example basic food products are inherently variable as natural
products, with differing water content, protein content, and other
aesthetic variation. Additionally, labor cost management, power
cost management, and variability in supply water, etc., provide for
a complex process where determination of the predictive variables,
sensed parameters to determine these, and optimization of
predicting in response to process variation are a difficult problem
to resolve. Food processing systems are often cost conscious, and
capital costs (e.g., for a robust network and computing system for
optimization) are not readily incurred. Further, a food processing
system may manufacture wide variance of products on similar or the
same production facilities, for example to support an entire
product line and/or due to seasonal variations, and accordingly a
predictive operation for one process may not support another
process well. Example systems include the pattern recognition
circuit determining the sensing parameter groups that provide a
strong signal response in target outcomes even in light of high
variability in system conditions. The pattern recognition circuit
can provide for numerous sensed group parameter options available
for different process conditions without requiring extensive
computing or data storage resources, and accordingly achieve
relevant predictions for a wide variety of operating conditions.
For example, control of and predictions for pressurization vessels,
stirrers, mixers, and/or thermic heating systems are amenable to
operations of the pattern recognition circuit, and/or a sensor
fusion with a temperature determination combined with a
non-temperature determination, a vibration determination combined
with a non-vibration determination, and/or a heat map combined with
a rate of change in the heat map and/or a non-heat map
determination. An example system includes a pattern recognition
circuit operation and/or a sensor fusion with a vibration
determination and a non-vibration determination, wherein predictive
information for a mixer and/or a stirrer is provided; and/or with a
pressure determination, a temperature determination, and/or a
non-pressure determination, wherein predictive information for a
pressurization vessel is provided.
[1145] Referencing FIG. 147, an example procedure 11038 includes an
operation 11040 to provide a number of sensors to an industrial
system including a number of components, each of the number of
sensors operatively coupled to at least one of the number of
components, an operation 11042 to interpret a number of sensor data
values in response to a sensed parameter group, the sensed
parameter group including at least one sensor of the number of
sensors, an operation 11044 to determine a recognized pattern value
in response to a least a portion of the number of sensor data
values, and an operation 11046 to provide a system characterization
value for the industrial system in response to the recognized
pattern value.
[1146] An example procedure 11038 further includes the operation
11046 to provide the system characterization value by performing an
operation such as: determining a predicted outcome for a process
associated with the industrial system; determining a predicted
future state for a process associated with the industrial system;
determining a predicted off-nominal operation for the process
associated with the industrial system; determining a prediction
value for one of the plurality of components; determining a future
state value for one of the plurality of components; determining an
anticipated maintenance health state information for one of the
plurality of components; determining a predicted maintenance
interval for at least one of the plurality of components;
determining a predicted off-nominal operation for one of the
plurality of components; determining a predicted fault operation
for one of the plurality of components; determining a predicted
exceedance value for one of the plurality of components; and/or
determining a predicted saturation value for one of the plurality
of sensors.
[1147] An example procedure 11038 includes an operation 11050 to
interpret external data and/or cloud-based data, and where the
operation 11044 to determine the recognized pattern value is
further in response to the external data and/or the cloud-based
data. An example procedure 11038 includes an operation to
iteratively improve pattern recognition operations in response to
the external data and/or the cloud-based data, for example by
operation 11048 to adjust the operation 11042 interpreting sensor
values, such as by updating the sensed parameter group. The
operation to iteratively improve pattern recognition may further
include repeating operations 11042 through 11048, periodically, at
selected intervals, in response to a system change, and/or in
response to a prediction value of a component, process, or the
system.
[1148] In embodiments, a system for data collection in an
industrial environment may comprise: an industrial system
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; a sensor communication circuit structured to interpret
a plurality of sensor data values in response to a sensed parameter
group, the sensed parameter group comprising at least one sensor of
the plurality of sensors; a pattern recognition circuit structured
to determine a recognized pattern value in response to a least a
portion of the plurality of sensor data values; and a system
characterization circuit structured to provide a system
characterization value for the industrial system in response to the
recognized pattern value. In embodiments, a characterization value
may include at least one characterization value selected from the
characterization values consisting of: a predicted outcome for a
process associated with the industrial system; a predicted future
state for a process associated with the industrial system; and a
predicted off-nominal operation for the process associated with the
industrial system. The system characterization value may include at
least one characterization value selected from the characterization
values consisting of: a prediction value for one of the plurality
of components; a future state value for one of the plurality of
components; an anticipated maintenance health state information for
one of the plurality of components; and a predicted maintenance
interval for at least one of the plurality of components. The
system characterization value may include at least one
characterization value selected from the characterization values
consisting of: a predicted off-nominal operation for one of the
plurality of components; a predicted fault operation for one of the
plurality of components; and a predicted exceedance value for one
of the plurality of components. The system characterization value
may include a predicted saturation value for one of the plurality
of sensors. A system collaboration circuit may be included that is
structured to interpret external data, and wherein the pattern
recognition circuit is further structured to determine the
recognized pattern value further in response to the external data.
The pattern recognition circuit may be further structured to
iteratively improve pattern recognition operations in response to
the external data. The external data may include at least one of:
an indicated component maintenance event; an indicated component
failure event; an indicated component wear value; an indicated
component operational exceedance value; and an indicated fault
value. The external data may include at least one of: an indicated
process failure value; an indicated process success value; an
indicated process outcome value; and an indicated process
operational exceedance value. The external data may include an
indicated sensor saturation value. A system collaboration circuit
may be included that is structured to interpret cloud-based data
comprising a second plurality of sensor data values, the second
plurality of sensor data values corresponding to at least one
offset industrial system, and wherein the pattern recognition
circuit is further structured to determine the recognized pattern
value further in response to the cloud-based data. The pattern
recognition circuit may be further structured to iteratively
improve pattern recognition operations in response to the
cloud-based data. The sensed parameter group may include a triaxial
vibration sensor. The sensed parameter group may include a
vibration sensor and a second sensor that is not a vibration
sensor, such as where the second sensor comprises a digital sensor.
The sensed parameter group may include a plurality of analog
sensors.
[1149] In embodiments, a method may comprise: providing a plurality
of sensors to an industrial system comprising a plurality of
components, each of the plurality of sensors operatively coupled to
at least one of the plurality of components; interpreting a
plurality of sensor data values in response to a sensed parameter
group, the sensed parameter group comprising at least one sensor of
the plurality of sensors; determining a recognized pattern value in
response to a least a portion of the plurality of sensor data
values; and providing a system characterization value for the
industrial system in response to the recognized pattern value. The
system characterization value may be provided by performing at
least one operation selected from the operations consisting of:
determining a prediction value for one of the plurality of
components; determining a future state value for one of the
plurality of components; determining an anticipated maintenance
health state information for one of the plurality of components;
and determining a predicted maintenance interval for at least one
of the plurality of components. The system characterization value
may be provided by performing at least one operation selected from
the operations consisting of: determining a predicted outcome for a
process associated with the industrial system; determining a
predicted future state for a process associated with the industrial
system; and determining a predicted off-nominal operation for the
process associated with the industrial system. The system
characterization value may be provided by performing at least one
operation selected from the operations consisting of: determining a
predicted off-nominal operation for one of the plurality of
components; determining a predicted fault operation for one of the
plurality of components; and determining a predicted exceedance
value for one of the plurality of components. The system
characterization value may be provided by determining a predicted
saturation value for one of the plurality of sensors. Determining
the recognized pattern value may be further in response to the
external data. Iteratively improving pattern recognition operations
may be provided in response to the external data. Interpreting the
external data may include at least one operation selected from the
operations consisting of: interpreting an indicated component
maintenance event; interpreting an indicated component failure
event; interpreting an indicated component wear value; interpreting
an indicated component operational exceedance value; and
interpreting an indicated fault value. Interpreting the external
data may include at least one operation selected from the
operations consisting of: interpreting an indicated process success
value; interpreting an indicated process failure value;
interpreting an indicated process outcome value; and interpreting
an indicated process operational exceedance value. Interpreting the
external data may include interpreting an indicated sensor
saturation value. Interpreting cloud-based data may include a
second plurality of sensor data values, the second plurality of
sensor data values corresponding to at least one offset industrial
system, and wherein determining the recognized pattern value is
further in response to the cloud-based data. Iteratively improving
pattern recognition operations may be provided in response to the
cloud-based data.
[1150] In embodiments, a system for data collection in an
industrial environment may comprise: an industrial system
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; a sensor communication circuit structured to interpret
a plurality of sensor data values in response to a sensed parameter
group, the sensed parameter group comprising at least one sensor of
the plurality of sensors; a means for determining a recognized
pattern value in response to at least a portion of the plurality of
sensor data values; and a means for providing a system
characterization value for the industrial system in response to the
recognized pattern value. The means for providing the system
characterization value may comprise a means for performing at least
one operation selected from the operations consisting of:
determining a predicted outcome for a process associated with the
industrial system; determining a predicted future state for a
process associated with the industrial system; and determining a
predicted off-nominal operation for the process associated with the
industrial system. The means for providing the system
characterization value may include a means for performing at least
one operation selected from the operations consisting of:
determining a prediction value for one of the plurality of
components; determining a future state value for one of the
plurality of components; determining an anticipated maintenance
health state information for one of the plurality of components;
and determining a predicted maintenance interval for at least one
of the plurality of components. The means for providing the system
characterization value may include a means for performing at least
one operation selected from the operations consisting of:
determining a predicted off-nominal operation for one of the
plurality of components; determining a predicted fault operation
for one of the plurality of components; and determining a predicted
exceedance value for one of the plurality of components. The means
for providing the system characterization value may include a means
for determining a predicted saturation value for one of the
plurality of sensors. A system collaboration circuit may be
provided that is structured to interpret external data, and wherein
the means for determining the recognized pattern value determines
the recognized pattern value further in response to the external
data. A means for iteratively improving pattern recognition
operations may be provided in response to the external data. The
external data may include at least one of: an indicated process
success value; an indicated process failure value; and an indicated
process outcome value. The external data may include at least one
of: an indicated component maintenance event; an indicated
component failure event; and an indicated component wear value. The
external data may include at least one of: an indicated process
operational exceedance value; an indicated component operational
exceedance value; and an indicated fault value. The external data
may include an indicated sensor saturation value. A system
collaboration circuit may be provided that is structured to
interpret cloud-based data comprising a second plurality of sensor
data values, the second plurality of sensor data values
corresponding to at least one offset industrial system, and wherein
the means for determining the recognized pattern value determines
the recognized pattern value further in response to the cloud-based
data. A means for iteratively improving pattern recognition
operations may be provided in response to the cloud-based data.
[1151] In embodiments, a system for data collection in an
industrial environment may comprise: a distillation column
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; a sensor communication circuit structured to interpret
a plurality of sensor data values in response to a sensed parameter
group, the sensed parameter group comprising at least one sensor of
the plurality of sensors; a pattern recognition circuit structured
to determine a recognized pattern value in response to a least a
portion of the plurality of sensor data values; and a system
characterization circuit structured to provide a system
characterization value for the distillation column in response to
the recognized pattern value. The plurality of components may
include a thermodynamic treatment component, and wherein the system
characterization value comprises at least one value selected from
the values consisting of: determining a prediction value for the
thermodynamic treatment component; determining a future state value
for the thermodynamic treatment component; determining an
anticipated maintenance health state information for the
thermodynamic treatment component; and determining a process rate
limitation according to a capacity of the thermodynamic treatment
component. The thermodynamic treatment component may include at
least one of a compressor or a boiler.
[1152] In embodiments, a system for data collection in an
industrial environment may comprise: a chemical process system
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; a sensor communication circuit structured to interpret
a plurality of sensor data values in response to a sensed parameter
group, the sensed parameter group comprising at least one sensor of
the plurality of sensors; a pattern recognition circuit structured
to determine a recognized pattern value in response to a least a
portion of the plurality of sensor data values; and a system
characterization circuit structured to provide a system
characterization value for the chemical process system in response
to the recognized pattern value. The chemical process system may
include one of a chemical plant, a pharmaceutical plant, or an oil
refinery. The system characterization value may include at least
one value selected from the values consisting of: a separation
process value comprising at least one of a capacity value or a
purity value; a side reaction process value comprising a side
reaction rate value; and a thermodynamic treatment value comprising
one of a capability, a capacity, and an anticipated maintenance
health for a thermodynamic treatment component.
[1153] A system for data collection in an industrial environment,
the system comprising:
[1154] an irrigation system comprising a plurality of components
including a pump, and a plurality of sensors each operatively
coupled to at least one of the plurality of components; a sensor
communication circuit structured to interpret a plurality of sensor
data values in response to a sensed parameter group, the sensed
parameter group comprising at least one sensor of the plurality of
sensors; a pattern recognition circuit structured to determine a
recognized pattern value in response to a least a portion of the
plurality of sensor data values; and a system characterization
circuit structured to provide a system characterization value for
the irrigation system in response to the recognized pattern value.
The system characterization value may include at least one of an
anticipated maintenance health value for the pump and a future
state value for the pump. The pattern recognition circuit may
determine an off-nominal process condition in response to the at
least a portion of the plurality of sensor data values, and wherein
the sensor communication circuit is further structured to change
the sensed parameter group in response to the off-nominal process
condition. The off-nominal process condition may include an
indication of below normal water feed availability, and wherein the
updated sensed parameter group comprises at least one sensor
selected from the sensors consisting of: a water level sensor, a
humidity sensor, and an auxiliary water level sensor.
[1155] As described elsewhere herein, feedback to various
intelligent and/or expert systems, control systems (including
remote and local systems, autonomous systems, and the like), and
the like, which may comprise rule-based systems, model-based
systems, artificial intelligence (AI) systems (including neural
nets, self-organizing systems, and others described throughout this
disclosure), and various combinations and hybrids of those
(collectively referred to herein as the "expert system" except
where context indicates otherwise), may include a wide range of
information, including measures such as utilization measures,
efficiency measures (e.g., power, financial such as reduction of
costs), measures of success in prediction or anticipation of states
(e.g., avoidance and mitigation of faults), productivity measures
(e.g., workflow), yield measures, profit measures, and the like, as
described herein. In embodiments feedback to the expert system may
be industry-specific, domain-specific, factory-specific,
machine-specific and the like.
[1156] Industry-specific feedback for the expert system may be
offered by a third party, such as a repair and maintenance
organization, manufacturer, one or more consortia, and the like, or
may be generated by one or more elements of the subject system
itself. Industry-specific feedback may be aggregated, such as into
one or more data structures, wherein the data are aggregated at the
component level, equipment level, factory/installation level,
and/or industry level. Users of the data structure(s) may access
data at any level (e.g., component, equipment, factory, industry,
etc.) Users may search the data structure(s) for
indicators/predictors based on or filtered by system conditions
specific to their need, or update an indicator/predictor with
proprietary data to customize the data structure to their industry.
In embodiments, the expert system may be seeded with
industry-specific feedback, such as in a deep learning fashion, to
provide an anticipated outcome or state and/or to perform actions
to optimize specific machines, devices, components, processes, and
the like.
[1157] In embodiments, feedback provided to the expert system may
be used in one or more smart bands to predict progress towards one
or more goals. The expert system may use the feedback to determine
a modification, alteration, addition, change, or the like to one or
more components of the system that provided the feedback, as
described elsewhere herein. Based on the industry-specific
feedback, the expert system may alter an input, a way of treating
or storing an input or output, a sensor or sensors used to provide
feedback, an operating parameter, a piece of equipment used in the
system, or any other aspect of the participants in the industrial
system that gave rise to the feedback. As described elsewhere
herein, the expert system may track multiple goals, such as with
one or more smart bands. Industry-specific feedback may be used in
or by the smart bands in predicting an outcome or state relating to
the one or more goals, and to recommend or instruct a change that
is directed in increasing a likelihood of achieving the outcome or
state.
[1158] For example, a mixer may be used in a food processing
environment or in a chemical processing environment, but the
feedback that is relevant in the food processing plant (e.g.,
required sterilization temperatures, food viscosity, particle
density (e.g., such as measured by an optical sensor), completion
of cooking (e.g., completion of reactions involved in baking),
sanitation (e.g., absence of pathogens) may be different than what
is relevant in the chemical processing plant (e.g., impeller speed,
velocity vectors, flow rate, absence of high contaminant levels, or
the like). This industry specific feedback is useful in optimizing
the operation of the mixer in its particular environment.
[1159] In another example, the expert system may use feedback from
agricultural systems to train a model related to an irrigation
system deployed in a field, wherein the industry-specific feedback
relates to one or more of an amount of water used across the
industry (e.g., such as measured by a flowmeter), a trend of water
usage over a time period (e.g., such as measured by a flowmeter), a
harvest amount (e.g., such as measured by a weight scale), an
insect infestation (e.g., such as identified and/or measured by a
drone imaging), a plant death (e.g., such as identified and/or
measured by drone imaging), and the like.
[1160] In another example of a fluid flow system (e.g., fan, pump
or compressor) controlling cooling in the manufacturing industry,
the expert system may use feedback from manufacturing of components
involving materials (e.g., polymers) that require cooling during
the manufacturing process, such as one or more of quality of output
product, strength of output product, flexibility of output product,
and the like (e.g., such as measured by a suite of sensors,
including densitometer, viscometer, size exclusion chromatograph,
and torque meter). If the sensors indicate that the polymer is
cooling too quickly during monomer conversion, the expert system
may relay an instruction to one or more of a fan, pump, or
compressor in the fluid flow system to decrease an aspect of its
operation in order to meet a quality goal.
[1161] In another example of a reciprocating compressor operating
in a refinery performing refinery processes (e.g., hydrotreating,
hydrocracking, isomerization, reforming), the expert system may use
feedback related to one or more of an amount of sulfur, nitrogen
and/or aromatics downstream of the compressor (e.g., such as
measured by a near infrared ("IR") analyzer), the cetane/octane
number or smoke point of a product (e.g., such as with an octane
analyzer), the density of a product (e.g., such as measured by a
densitometer), byproduct gas amounts (e.g., such as measured by an
electrochemical gas sensor), and the like. In this example, as
feedback is received during isomerization of butane to isobutene by
an inline near IR analyzer measuring the amount and/or quality of
isobutene, the expert system may determine that the performance of
one or more components of the isomerization system, including the
reciprocating compressor, should be altered in order to meet a
production goal.
[1162] In another example of a vacuum distillation unit operating
in a refinery, the expert system may use feedback related to an
amount of raw gasoline recovered (e.g., such as by measuring the
volume or composition of various fractions using IR), boiling point
of recovered fractions (e.g., such as with a boiling point
analyzer), a vapor cooling rate (e.g., such as measured by
thermometer), and the like. In this example, as feedback is
received during vacuum distillation to recover diesel, as the
amounts recovered indicate off-nominal rations of production, the
expert system may instruct the vacuum distillation unit to alter a
feedstock source and initiate more detailed analysis of the prior
feedstock.
[1163] In yet another example of a pipeline in a refinery, the
expert system may use feedback related to flow type (e.g., bubble,
stratified, slug, annular, transition, mist) of hydrocarbon
products (e.g., such as measured by dye tracing), flow rate, vapor
velocity (such as with a flow meter), vapor shear, and the like. In
this example, as feedback is received during operation of the
pipeline regarding the flow type and its rate, modifications may be
recommended by the expert system to improve the flow through the
pipeline.
[1164] In still another example of a paddle-type or anchor-type
agitator/mixer in a pharmaceutical plant, the expert system may use
feedback related to degree of mixing of high-viscosity liquids,
heating of medium- to low-viscosity liquids, a density of the
mixture, a growth rate of an organism in the mixture, and the like.
In this example, as feedback is received during operation of the
agitator that a bacterial growth rate is too high (such as measured
with a spectrophotometer), the expert system may instruct the
agitator to reduce its speed to limit the amount of air being added
to the mixture or growth substrate.
[1165] In a further example of a pressure reactor in a chemical
processing plant, the expert system may use feedback related to a
catalytic reaction rate (such as measured by a mass spectrometer),
a particle density (such as measured by a densitometer), a
biological growth rate (such as measured by a spectrophotometer),
and the like. In this example, as feedback is received during
operation of the pressure reactor that the particle density and
biological growth rate are off-nominal, the expert system may
instruct the pressure reactor to modify one or more operational
parameters, such as a reduction in pressure, an increase in
temperature, an increase in volume of the reaction, and the
like.
[1166] In another example of a gas agitator operating in a chemical
processing plant, the expert system may use feedback related to
effective density of a gassed liquid, a viscosity, a gas pressure,
and the like, as measured by appropriate sensors or equipment. In
this example, as feedback is received during operation of the gas
agitator, the expert system may instruct the gas agitator to modify
one or more operational parameters, such as to increase or decrease
a rate of agitation.
[1167] In still another example of a pump blasting liquid type
agitator in a chemical processing plant, the expert system may use
feedback related to a viscosity of a mixture, an optical density of
a growth medium, and a temperature of a solution. In this example,
as feedback is received during operation of the agitator, the
expert system may instruct the agitator to modify one or more
operational parameters, such as to increase or decrease a rate of
agitation and/or inject additional heat.
[1168] In yet another example of a turbine type agitator in a
chemical processing plant, the expert system may use feedback
related to a vibration noise, a reaction rate of the reactants, a
heat transfer, or a density of a suspension. In this example, as
feedback is received during operation of the agitator, the expert
system may instruct the agitator to modify one or more operational
parameters, such as to increase or decrease a rate of agitation
and/or inject an additional amount of catalyst.
[1169] In yet another example of a static agitator mixing monomers
in a chemical processing plant to produce a polymer, the expert
system may use feedback related to the viscosity of the polymer,
color of the polymer, reactivity of the polymer and the like to
iterate to a new setting or parameter for the agitator, such as for
example, a setting that alters the Reynolds number, an increase in
temperature, a pressure increase, and the like.
[1170] In a further example of a catalytic reactor in a chemical
processing plant, the expert system may use feedback related to a
reaction rate, a product concentration, a product color, and the
like. In this example, as feedback is received during operation of
the catalytic reactor, the expert system may instruct the reactor
to modify one or more operational parameters, such as to increase
or decrease a temperature and/or inject an additional amount of
catalyst.
[1171] In yet a further example of a thermic heating systems in a
chemical processing or food plant, the expert system may use
feedback related to BTUs out of the system, a flow rate, and the
like. In this example, as feedback is received during operation of
the thermic heating system, the expert system may instruct the
system to modify one or more operational parameters, such as to
change the input feedstock, to increase the flow of the feedstock,
and the like.
[1172] In still a further example of using boiler feed water in a
refinery, the expert system may use feedback related to an aeration
level, a temperature, and the like. In this example, as feedback is
received related to the boiler feed water, the expert system may
instruct the system to modify one or more operational parameters of
a boiler, such as to increase a reduction in aeration, to increase
the flow of the feed water, and the like.
[1173] In still a further example of a storage tank in a refinery,
the expert system may use feedback related to a temperature, a
pressure, a flow rate out of the tank, and the like. In this
example, as feedback is received related to the storage tank, the
expert system may instruct the system to modify one or more
operational parameters of, such as to increase cooling or heating
begin agitation, and the like.
[1174] In an example of a condensate/make-up water system in a
power station that condenses steam from turbines and recirculates
it back to a boiler feeder along with make-up water, the expert
system may use feedback related to measuring inward air leaks, heat
transfer, and make-up water quality. In this example, as feedback
is received related to the condensate/make-up water system, the
expert system may instruct the system to increase a purification of
the make-up water, bring a vacuum pump online, and the like.
[1175] In another example of a stirrer in a food plant, the expert
system may use feedback related to a viscosity of the food, a color
of the food, a temperature of the food, and the like. In this
example, as feedback is received, the expert system may instruct
the stirrer to speed up or slow down, depending on the predicted
success in reaching a goal.
[1176] In another example of a pressure cooker in a food plant, the
expert system may use feedback related to a viscosity of the food,
a color of the food, a temperature of the food, and the like. In
this example, as feedback is received, the expert system may
instruct the pressure cooker to continue operating, increase a
temperature, or the like, depending on the predicted success in
reaching a goal.
[1177] In an embodiment, a system 11100 for data collection in an
industrial environment may include a plurality of input sensors
11102 communicatively coupled to a controller 11106, a data
collection circuit 11104 structured to collect output data 11108
from the input sensors 11102, and a machine learning data analysis
circuit 11110 structured to receive the output data 11108 and learn
received output data patterns 11112 indicative of an outcome,
wherein the machine learning data analysis circuit 11110 is
structured to learn received output data patterns 11112 by being
seeded with a model 11114 based on industry-specific feedback
11118. The model 11114 may be a physical model, an operational
model, or a system model. The industry-specific feedback 11118 may
be one or more of a utilization measure, an efficiency measure
(e.g., power and/or financial), a measure of success in prediction
or anticipation of states (e.g., an avoidance and mitigation of
faults), a productivity measure (e.g., a workflow), a yield
measure, and a profit measure. The industry-specific feedback 11118
includes an amount of power generated by a machine about which the
input sensors provide information during operation of the machine.
The industry-specific feedback 11118 includes a measure of the
output of an assembly line about which the input sensors provide
information. The industry-specific feedback 11118 includes a
failure rate of units of product produced by a machine about which
the input sensors provide information. The industry-specific
feedback 11118 includes a fault rate of a machine about which the
input sensors provide information. The industry-specific feedback
11118 includes the power utilization efficiency of a machine about
which the input sensors provide information, wherein the machine is
one of a turbine, a transformer, a generator, a compressor, one
that stores energy, and one that includes power train components
(e.g., the rate of extraction of a material by a machine about
which the input sensors provide information, the rate of production
of a gas by a machine about which the input sensors provide
information, the rate of production of a hydrocarbon product by a
machine about which the input sensors provide information), and the
rate of production of a chemical product by a machine about which
the input sensors provide information. The machine learning data
analysis circuit 11110 may be further structured to learn received
output data patterns 11112 based on the outcome. The system 11100
may keep or modify operational parameters or equipment. The
controller 11106 may adjust the weighting of the machine learning
data analysis circuit 11110 based on the learned received output
data patterns 11112 or the outcome, collect more/fewer data points
from the input sensors based on the learned received output data
patterns 11112 or the outcome, change a data storage technique for
the output data 11108 based on the learned received output data
patterns 11112 or the outcome, change a data presentation mode or
manner based on the learned received output data patterns 11112 or
the outcome, and apply one or more filters (low pass, high pass,
band pass, etc.) to the output data 11108. In embodiments, the
system 11100 may remove/re-task under-utilized equipment based on
one or more of the learned received output data patterns 11112 and
the outcome. The machine learning data analysis circuit 11110 may
include a neural network expert system. The input sensors may
measure vibration and noise data. The machine learning data
analysis circuit 11110 may be structured to learn received output
data patterns 11112 indicative of progress/alignment with one or
more goals/guidelines (e.g., which may be determined by a different
subset of the input sensors). The machine learning data analysis
circuit 11110 may be structured to learn received output data
patterns 11112 indicative of an unknown variable. The machine
learning data analysis circuit 11110 may be structured to learn
received output data patterns 11112 indicative of a preferred input
among available inputs. The machine learning data analysis circuit
11110 may be structured to learn received output data patterns
11112 indicative of a preferred input data collection band among
available input data collection bands. The machine learning data
analysis circuit 11110 may be disposed in part on a machine, on one
or more data collectors, in network infrastructure, in the cloud,
or any combination thereof. The system 11100 may be deployed on the
data collection circuit 11104. The system 11100 may be distributed
between the data collection circuit 11104 and a remote
infrastructure. The data collection circuit 11104 may include a
data collector.
[1178] In embodiments, a system 11100 for data collection in an
industrial environment may include a plurality of input sensors
11102 communicatively coupled to a controller 11106, a data
collection circuit 11104 structured to collect output data 11108
from the input sensors, and a machine learning data analysis
circuit 11110 structured to receive the output data 11108 and learn
received output data patterns 11112 indicative of an outcome,
wherein the machine learning data analysis circuit 11110 is
structured to learn received output data patterns 11112 by being
seeded with a model 11114 based on a utilization measure.
[1179] In embodiments, a system 11100 for data collection in an
industrial environment may include a plurality of input sensors
11102 communicatively coupled to a controller 11106, a data
collection circuit 11104 structured to collect output data 11108
from the input sensors, and a machine learning data analysis
circuit 11110 structured to receive the output data 11108 and learn
received output data patterns 11112 indicative of an outcome,
wherein the machine learning data analysis circuit 11110 is
structured to learn received output data patterns 11112 by being
seeded with a model 11114 based on an efficiency measure.
[1180] In embodiments, a system 11100 for data collection in an
industrial environment may include a plurality of input sensors
11102 communicatively coupled to a controller 11106, a data
collection circuit 11104 structured to collect output data 11108
from the input sensors, and a machine learning data analysis
circuit 11110 structured to receive the output data 11108 and learn
received output data patterns 11112 indicative of an outcome,
wherein the machine learning data analysis circuit 11110 is
structured to learn received output data patterns 11112 by being
seeded with a model 11114 based on a measure of success in
prediction or anticipation of states.
[1181] In embodiments, a system 11100 for data collection in an
industrial environment may include a plurality of input sensors
11102 communicatively coupled to a controller 11106, a data
collection circuit 11104 structured to collect output data 11108
from the input sensors, and a machine learning data analysis
circuit 11110 structured to receive the output data 11108 and learn
received output data patterns 11112 indicative of an outcome,
wherein the machine learning data analysis circuit 11110 is
structured to learn received output data patterns 11112 by being
seeded with a model 11114 based on a productivity measure.
[1182] Clause 1. In embodiments, a system for data collection in an
industrial environment, comprising: a plurality of input sensors
communicatively coupled to a controller; a data collection circuit
structured to collect output data from the input sensors; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns indicative of
an outcome, wherein the machine learning data analysis circuit is
structured to learn received output data patterns by being seeded
with a model based on industry-specific feedback. 2. The system of
clause 1, wherein the model is a physical model, an operational
model, or a system model. 3. The system of clause 1, wherein the
industry-specific feedback is a utilization measure. 4. The system
of clause 1, wherein the industry-specific feedback is an
efficiency measure. 5. The system of clause 4, wherein the
efficiency measure is one of power and financial. 6. The system of
clause 1, wherein the industry-specific feedback is a measure of
success in prediction or anticipation of states. 7. The system of
clause 6, wherein the measure of success is an avoidance and
mitigation of faults. 8. The system of clause 1, wherein the
industry-specific feedback is a productivity measure. 9. The system
of clause 8, wherein the productivity measure is a workflow. 10.
The system of clause 1, wherein the industry-specific feedback is a
yield measure. 11. The system of clause 1, wherein the
industry-specific feedback is a profit measure. 12. The system of
clause 1, wherein the machine learning data analysis circuit is
further structured to learn received output data patterns based on
the outcome. 13. The system of clause 1, wherein the system keeps
or modifies operational parameters or equipment. 14. The system of
clause 1, wherein the controller adjusts the weighting of the
machine learning data analysis circuit based on the learned
received output data patterns or the outcome. 15. The system of
clause 1, wherein the controller collects more/fewer data points
from the input sensors based on the learned received output data
patterns or the outcome. 16. The system of clause 1, wherein the
controller changes a data storage technique for the output data
based on the learned received output data patterns or the outcome.
17. The system of clause 1, wherein the controller changes a data
presentation mode or manner based on the learned received output
data patterns or the outcome. 18. The system of clause 1, wherein
the controller applies one or more filters (low pass, high pass,
band pass, etc.) to the output data. 19. The system of clause 1,
wherein the system removes/re-tasks under-utilized equipment based
on one or more of the learned received output data patterns and the
outcome. 20. The system of clause 1, wherein the machine learning
data analysis circuit comprises a neural network expert system. 21.
The system of clause 1, wherein the input sensors measure vibration
and noise data. 22. The system of clause 1, wherein the machine
learning data analysis circuit is structured to learn received
output data patterns indicative of progress/alignment with one or
more goals/guidelines. 23. The system of clause 22, wherein
progress/alignment of each goal/guideline is determined by a
different subset of the input sensors. 24. The system of clause 1,
wherein the machine learning data analysis circuit is structured to
learn received output data patterns indicative of an unknown
variable. 25. The system of clause 1, wherein the machine learning
data analysis circuit is structured to learn received output data
patterns indicative of a preferred input among available inputs.
26. The system of clause 1, wherein the machine learning data
analysis circuit is structured to learn received output data
patterns indicative of a preferred input data collection band among
available input data collection bands. 27. The system of clause 1,
wherein the machine learning data analysis circuit is disposed in
part on a machine, on one or more data collectors, in network
infrastructure, in the cloud, or any combination thereof. 28. The
system of clause 1, wherein the system is deployed on the data
collection circuit. 29. The system of clause 1, wherein the system
is distributed between the data collection circuit and a remote
infrastructure. 30. The system of clause 1, wherein the
industry-specific feedback includes an amount of power generated by
a machine about which the input sensors provide information during
operation of the machine. 31. The system of clause 1, wherein the
industry-specific feedback includes a measure of the output of an
assembly line about which the input sensors provide information.
32. The system of clause 1, wherein the industry-specific feedback
includes a failure rate of units of product produced by a machine
about which the input sensors provide information. 33. The system
of clause 1, wherein the industry-specific feedback includes a
fault rate of a machine about which the input sensors provide
information. 34. The system of clause 1, wherein the
industry-specific feedback includes the power utilization
efficiency of a machine about which the input sensors provide
information. 35. The system of clause 34, wherein the machine is a
turbine. 36. The system of clause 34, wherein the machine is a
transformer. 37. The system of clause 34, wherein the machine is a
generator. 38. The system of clause 34, wherein the machine is a
compressor. 39. The system of clause 34, wherein the machine stores
energy. 40. The system of clause 1, wherein the machine includes
power train components. 41. The system of clause 34, wherein the
industry-specific feedback includes the rate of extraction of a
material by a machine about which the input sensors provide
information. 42. The system of clause 34, wherein the
industry-specific feedback includes the rate of production of a gas
by a machine about which the input sensors provide information. 43.
The system of clause 34, wherein the industry-specific feedback
includes the rate of production of a hydrocarbon product by a
machine about which the input sensors provide information. 44. The
system of clause 34, wherein the industry-specific feedback
includes the rate of production of a chemical product by a machine
about which the input sensors provide information. 45. The system
of clause 1, wherein the data collection circuit comprises a data
collector. 46. A system for data collection in an industrial
environment, comprising: a plurality of input sensors
communicatively coupled to a controller; a data collection circuit
structured to collect output data from the input sensors; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns indicative of
an outcome, wherein the machine learning data analysis circuit is
structured to learn received output data patterns by being seeded
with a model based on a utilization measure. 47. A system for data
collection in an industrial environment, comprising: a plurality of
input sensors communicatively coupled to a controller; a data
collection circuit structured to collect output data from the input
sensors; and a machine learning data analysis circuit structured to
receive the output data and learn received output data patterns
indicative of an outcome, wherein the machine learning data
analysis circuit is structured to learn received output data
patterns by being seeded with a model based on an efficiency
measure. 48. A system for data collection in an industrial
environment, comprising: a plurality of input sensors
communicatively coupled to a controller; a data collection circuit
structured to collect output data from the input sensors; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns indicative of
an outcome, wherein the machine learning data analysis circuit is
structured to learn received output data patterns by being seeded
with a model based on a measure of success in prediction or
anticipation of states. 49. A system for data collection in an
industrial environment, comprising: a plurality of input sensors
communicatively coupled to a controller; a data collection circuit
structured to collect output data from the input sensors; and a
machine learning data analysis circuit structured to receive the
output data and learn received output data patterns indicative of
an outcome, wherein the machine learning data analysis circuit is
structured to learn received output data patterns by being seeded
with a model based on a productivity measure.
[1183] In embodiments, a system for data collection in an
industrial environment may include an expert system graphical user
interface in which a user may, by interacting with a graphical user
interface element, set a parameter of a data collection band for
collection by a data collector. The parameter may relate to at
least one of setting a frequency range for collection and setting
an extent of granularity for collection.
[1184] In embodiments, a system for data collection in an
industrial environment may include an expert system graphical user
interface in which a user may, by interacting with a graphical user
interface element, identify a set of sensors among a larger set of
available sensors for collection by a data collector. The user
interface may include views of available data collectors, their
capabilities, one or more corresponding smart bands, and the
like.
[1185] In embodiments, a system for data collection in an
industrial environment may include an expert system graphical user
interface in which a user may, by interacting with a graphical user
interface element, select a set of inputs to be multiplexed among a
set of available inputs.
[1186] In embodiments, a system for data collection in an
industrial environment may include an expert system graphical user
interface in which a user may, by interacting with a graphical user
interface element, select a component of an industrial machine
displayed in the graphical user interface for data collection, view
a set of sensors that are available to provide data about the
industrial machine, and select a subset of sensors for data
collection.
[1187] In embodiments, a system for data collection in an
industrial environment may include an expert system graphical user
interface in which a user may, by interacting with a graphical user
interface element, view a set of indicators of fault conditions of
one or more industrial machines, where the fault conditions are
identified by application of an expert system to data collected
from a set of data collectors. In embodiments, the fault conditions
may be identified by manufacturers of portions of the one or more
industrial machines. The fault conditions may be identified by
analysis of industry trade data, third-party testing agency data,
industry standards, and the like. In embodiments, a set of
indicators of fault conditions of one or more industrial machines
may include indicators of stress, vibration, heat, wear, ultrasonic
signature, operational deflection shape, and the like, optionally
including any of the widely varying conditions that can be sensed
by the types of sensors described throughout this disclosure and
the documents incorporated herein by reference.
[1188] In embodiments, a system for data collection in an
industrial environment may include an expert graphical user
interface that enables a user to select from a list of component
parts of an industrial machine for establishing smart-band
monitoring and in response thereto presents the user with at least
one smart-band definition of an acceptable range of values for at
least one sensor of the industrial machine and a list of correlated
sensors from which data will be gathered and analyzed when an out
of acceptable range condition is detected from the at least one
sensor.
[1189] In embodiments, a system for data collection in an
industrial environment may include an expert graphical user
interface that enables a user to select from a list of conditions
of an industrial machine for establishing smart-band monitoring
and, in response thereto, presents the user with at least one
smart-band definition of an acceptable range of values for at least
one sensor of the industrial machine and a list of correlated
sensors from which data will be gathered and analyzed when an out
of acceptable range condition is detected from the at least one
sensor.
[1190] In embodiments, a system for data collection in an
industrial environment may include an expert graphical user
interface that enables a user to select from a list of reliability
measures of an industrial machine for establishing smart-band
monitoring and, in response thereto, presents the user with at
least one smart-band definition of an acceptable range of values
for at least one sensor of the industrial machine and a list of
correlated sensors from which data will be gathered and analyzed
when an out of acceptable range condition is detected from the at
least one sensor. In the system, the reliability measures may
include one or more of industry average data, manufacturer's
specifications, material specifications, recommendations, and the
like. In embodiments, reliability measures may include measures
that correlate to failures, such as stress, vibration, heat, wear,
ultrasonic signature, operational deflection shape effect, and the
like. In embodiments, manufacturer's specifications may include
cycle count, working time, maintenance recommendations, maintenance
schedules, operational limits, material limits, warranty terms, and
the like. In embodiments, the sensors in the industrial environment
may be correlated to manufacturer's specifications by associating a
condition being sensed by the sensor to a specification type. In
embodiments, a non-limiting example of correlating a sensor to a
manufacturer's specification may include a duty cycle specification
being correlated to a sensor that detects revolutions of a moving
part. In embodiments, a temperature specification may correlate to
a thermal sensor disposed to sense an ambient temperature proximal
to the industrial machine.
[1191] In embodiments, a system for data collection in an
industrial environment may include an expert graphical user
interface that automatically creates a smart-band group of sensors
disposed in the industrial environment in response to receiving a
condition of the industrial environment for monitoring and an
acceptable range of values for the condition.
[1192] In embodiments, a system for data collection in an
industrial environment may include an expert graphical user
interface that presents a representation of components of an
industrial machine deployable in the industrial environment on an
electronic display, and in response to a user selecting one or more
of the components, searches a database of industrial machine
failure modes for modes involving the selected component(s) and
conditions associated with the failure mode(s) to be monitored, and
further identifies a plurality of sensors in, on, or available to
be disposed on the presented machine representation from which data
will automatically be captured when the condition(s) to be
monitored are detected to be outside of an acceptable range. In
embodiments, the identified plurality of sensors includes at least
one sensor through which the condition(s) will be monitored.
[1193] In embodiments, a system for data collection in an
industrial environment may include a user interface for working
with smart bands that may facilitate a user identifying sensors to
include in a smart band group of sensors by selecting sensors
presented on a map of a machine in the environment. A user may be
guided to select among a subset of all possible sensors based on
smart band criteria, such as types of sensor data required for the
smart band. A smart band may be focused on detecting trending
conditions in a portion of the industrial environment; therefore,
the user interface may direct the user choose among an identified
subset of sensors, such as by only allowing sensors proximal to the
smart band directed portion of the environment to be selectable in
the user interface.
[1194] In embodiments, a smart band data collection configuration
and deployment user interface may include views of components in an
industrial environment and related available sensors. In
embodiments, in response to selection of a component part of an
industrial machine depicted in the user interface, sensors
associated with smart band data collection for the component part
may be highlighted so that the user may select one or more of the
sensors. User selection in this context may comprise a verification
of an automatic selection of sensors, or manually identifying
sensors to include in the smart band sensor group.
[1195] In embodiments, in response to selection of a smart band
condition, such as trending of bearing temperature, a user
interface for smart band configuration and use may automatically
identify and present sensors that contribute to smart band analysis
for the condition. A user may responsive to this presentation of
sensors, confirm or otherwise acknowledge one or more sensors
individually or as a set to be included in the smart band data
collection group.
[1196] In embodiments, a smart band user interface may present
locations of industrial machines in an industrial environment on a
map. The locations may be annotated with indicators of smart band
data collection templates that are configured for collecting smart
band data for the machines at the annotated locations. The
locations may be color coded to reflect a degree of smart band
coverage for a machine at the location. In embodiments, a location
of a machine with a high degree of smart band coverage may be
colored green, whereas a location of a machine with low smart band
coverage may be colored red or some other contrasting color. Other
annotations, such as visual annotations may be used. A user may
select a machine at a location and by dragging the selected machine
to a location of a second machine, effectively configure smart
bands for the second machine that correspond to smart bands for the
first machine. In this way, a user may configure several smart band
data collection templates for a newly added machine or a new
industrial environment and the like.
[1197] In embodiments, various configurations and selections of
smart bands may be stored for use throughout a data collection
platform, such as for selecting templates for sensing, templates
for routing, provisioning of devices and the like, as well as for
direct the placement of sensors, such as by personnel or by
machines, such as autonomous or remote-control drones.
[1198] In embodiments, a smart band user interface may present a
map of an industrial environment that may include industrial
machines, machine-specific data collectors, mobile data collectors
(robotic and human), and the like. A user may view a list of smart
band data collection actions to be performed and may select a data
collection resource set to undertake the collection. In an example,
a guided mobile robot may be equipped with data collection systems
for collecting data for a plurality of smart band data sets. A user
may view an industrial environment with which the robot is
associated and assign the robot to perform a smart band data
collection activity by selecting the robot, a smart band data
collection template, and a location in the industrial environment,
such as a machine or a part of a machine. The user interface may
provide a status of the collection undertaking so that the user can
be informed when the data collection is complete.
[1199] In embodiments, a smart band operation management user
interface may include presentation of smart band data collection
activity, analysis of results, actions taken based on results,
suggestions for changes to smart band data collection (e.g.,
addition of sensors to a smart band collection template, increasing
duration of data collection for a template-specific collection
activity), and the like. The user interface may facilitate "what
if" type analysis by presenting potential impacts on reliability,
costs, resource utilization, data collection tradeoffs, maintenance
schedule impacts, risk of failure (increase/decrease), and the like
in response to a user's attempt to make a change to a smart band
data collection template, such as a user relaxing a threshold for
performing smart band data collection and the like. In embodiments,
a user may select or enter a target budget for preventive
maintenance per unit time (e.g., per month, quarter, and the like)
into the user interface and an expert system of the user interface
may recommend a smart band data collection template and thresholds
for complying with the budget.
[1200] In embodiments, a smart band user interface may facilitate a
user configuring a system for data collection in an industrial
environment for smart band data gathering. The user interface may
include display of industrial machine components, such as motors,
linkages, bearings, and the like that a user may select. In
response to such a selection, an expert system may work with the
user interface to present a list of potential failure conditions
related to the part to monitor. The user may select one or more
conditions to monitor. The user interface may present the
conditions to monitor as a set that the user may be asked to
approve. The user may indicate acceptance of the set or of select
conditions in the set monitor. As a follow-on to a user
selection/approval of one or more conditions to monitor, the user
interface may display a map of relevant sensors available in the
industrial environment for collecting data as a smart band group of
sensors. The relevant sensors may be associated with one or more
parts (e.g., the part(s) originally selected by the user), one or
more failure conditions, and the like.
[1201] In embodiments, the expert system may compare the relevant
sensors in the environment to a preferred set of sensors for smart
band monitoring of the failure condition(s) and provide feedback to
the user, such as a confidence factor for performing smart band
monitoring based on the available sensors for the failure
condition(s). The user may evaluate the failure condition and smart
band analysis information presented and may take an action in the
user interface, such as approving the relevant sensors. In
response, a smart band data collection template for configuring the
data collection system may be created. In embodiments, a smart band
data collection template may be created independently of a user
approval. In such embodiments, the user may indicate explicitly or
implicitly via approval of the smart band analysis information an
approval of the created template.
[1202] In embodiments, a smart band user interface may work with an
expert system to present candidate portions of an industrial
machine in an industrial environment for smart band condition
monitoring based on information such as manufacturer's
specifications, statistical information derived from real-world
experience with similar industrial machines, and the like. In
embodiments, the user interface may permit a user to select certain
aspects of the smart band data collection and analysis process
including--for example, a degree of reliability/failure risk to
monitor (e.g., near failure, best performance, industry average,
and the like). In response thereto, the expert system may adjust an
aspect of the smart band analysis, such as a range of acceptable
value to monitor, a monitor frequency, a data collection frequency,
a data collection amount, a priority for the data collection
activity (e.g., effectively a priority of a template for data
collection for the smart band), weightings of data from sensors
(e.g., specific sensors in the group, types of sensors, and the
like).
[1203] In embodiments, a smart bands user interface may be
structured to allow a user to let an expert system recommend one or
more smart bands to implement based on a range of comparative data
that the user might prioritize, such as industry average data,
industry best data, near-by comparable machines, most similarly
configured machines, and the like. Based on the comparative data
weighting, the expert system may use the user interface to
recommend one or more smart band templates that align with the
weighting to the user, who may take an action in the user
interface, such as approving one or more of the recommended
templates for use.
[1204] In embodiments, a user interface for configuring arrangement
of sensors in an industrial environment may include recommendations
by industrial environment equipment suppliers (e.g., manufacturers,
wholesalers, distributors, dealers, third-party consultants, and
the like) of group(s) of sensors to include for performing smart
band analysis of components of the industrial equipment. The
information may be presented to a user as data collection
template(s) that the user may indicate as being accepted/approved,
such as by positioning a graphic representing a template(s) over a
portion of the industrial equipment.
[1205] In embodiments, a smart band discovery portal may facilitate
sharing of smart band related information, such as recommendations,
actual use cases, results of smart band data collection and
processing, and the like. The discovery portal may be embodied as a
panel in a smart band user interface.
[1206] In embodiments, a smart band assessment portal may
facilitate assessment of smart band-based data collection and
analysis. Content that may be presented in such a portal may
include depictions of uses of existing smart band templates for one
or more industrial machines, industrial environments, industries,
and the like. A value of a smart band may be ascribed to each smart
band in the portal based, for example, on historical use and
outcomes. A smart band assessment portal may also include
visualization of candidate sensors to include in a smart band data
collection template based on a range of factors including ascribed
value, preventive maintenance costs, failure condition being
monitored, and the like.
[1207] In embodiments, a smart bands graphical user interface
associated with a system for data collection in an industrial
environment may be deployed for industrial components, such as of
factory-based air conditioning units. A user interface of a system
for data collection for smart band analysis of air conditioning
units may facilitate graphical configuration of smart band data
collection templates and the like for specific air conditioning
system installations. In embodiments, major components of an air
conditioning system, such as a compressor, condenser, heat
exchanger, ducting, coolant regulators, filters, fans, and the like
along with corresponding sensors for a particular installation of
the air conditioning system may be depicted in a user interface. A
user may select one or more of these components in the user
interface for configuring a system for smart band data collection.
In response to the user selecting, for example, a coolant
compressor, sensors associated with the compressor may be
automatically identified in the user interface. The user may be
presented with a recommended data collection template to perform
smart band data collection for the selected compressor.
Alternatively, the user may request a candidate collection template
from a community of smart band users, such as through a smart band
template sharing panel of the user interface. Once a template is
selected, the user interface may offer the user customization
options, such as frequency of collection, degree of reliability to
monitor, and the like. Upon final acceptance of the template, the
user interface may interact with a data collection system of the
installed air conditioning system (if such a system is available)
to implement the data collection template and provide an indication
to the user of the result of implementing the template. In response
thereto, the user may make a final approval of the template for use
with the air conditioning unit.
[1208] In embodiments, a smart bands graphical user interface
associated with a system for data collection in an industrial
environment may be deployed for oil and gas refinery-based
chillers. A user interface of a system for data collection for
smart band analysis of refinery-based chillers may facilitate
graphical configuration of smart band data collection templates and
the like for specific refinery-based chiller installations. In
embodiments, major components of a refinery-based chiller including
heat exchangers, compressors, water regulators and the like along
with corresponding sensors for the particular installation of the
refinery-based chiller may be depicted in a user interface. A user
may select one or more of these components in the user interface
for configuring a system for smart band data collection. In
response to the user selecting, for example, water regulators,
sensors associated with the water regulators may be automatically
identified in the user interface. The user may be presented with a
recommended data collection template to perform smart band data
collection for the selected component. Alternatively, the user may
request a candidate collection template from a community of smart
band users, such as through a smart band template sharing panel of
the user interface. Once a template is selected, the user interface
may offer the user customization options, such as frequency of
collection, degree of reliability to monitor, and the like. Upon
final acceptance of the template, the user interface may interact
with a data collection system of the installed refinery-based
chiller (if such a system is available) to implement the data
collection template and provide an indication to the user of the
result of implementing the template. In response thereto, the user
may make a final approval of the template for use with the
refinery-based chiller.
[1209] In embodiments, a smart bands graphical user interface
associated with a system for data collection in an industrial
environment may be deployed for automotive production line robotic
assembly systems. A user interface of a system for data collection
for smart band analysis of production line robotic assembly systems
may facilitate graphical configuration of smart band data
collection templates and the like for specific production line
robotic assembly system installations. In embodiments, major
components of a production line robotic assembly system including
motors, linkages, tool handlers, positioning systems and the like
along with corresponding sensors for the particular installation of
the production line robotic assembly system may be depicted in a
user interface. A user may select one or more of these components
in the user interface for configuring a system for smart band data
collection. In response to the user selecting, for example, robotic
linkage sensors associated with the robotic linkages may be
automatically identified in the user interface. The user may be
presented with a recommended data collection template to perform
smart band data collection for the selected component.
Alternatively, the user may request a candidate collection template
from a community of smart band users, such as through a smart band
template sharing panel of the user interface. Once a template is
selected, the user interface may offer the user customization
options, such as frequency of collection, degree of reliability to
monitor, and the like. Upon final acceptance of the template, the
user interface may interact with a data collection system of the
installed production line robotic assembly system (if such a system
is available) to implement the data collection template and provide
an indication to the user of the result of implementing the
template. In response thereto, the user may make a final approval
of the template for use with the production line robotic assembly
system.
[1210] In embodiments, a smart bands graphical user interface
associated with a system for data collection in an industrial
environment may be deployed for automotive production line robotic
assembly systems. A user interface of a system for data collection
for smart band analysis of production line robotic assembly systems
may facilitate graphical configuration of smart band data
collection templates and the like for specific production line
robotic assembly system installations. In embodiments, major
components of construction site boring machinery, such as the
cutter head, which itself is a subsystem that may have many
components, control systems, debris handling and conveying
components, precast concrete delivery and installation subsystems
and the like along with corresponding sensors for the particular
installation of the production line robotic assembly system may be
depicted in a user interface. A user may select one or more of
these components in the user interface for configuring a system for
smart band data collection. In response to the user selecting, for
example, debris handling components sensors associated with the
debris handling components, such as a conveyer may be automatically
identified in the user interface. The user may be presented with a
recommended data collection template to perform smart band data
collection for the selected component. Alternatively, the user may
request a candidate collection template from a community of smart
band users, such as through a smart band template sharing panel of
the user interface. Once a template is selected, the user interface
may offer the user customization options, such as frequency of
collection, degree of reliability to monitor, and the like. Upon
final acceptance of the template, the user interface may interact
with a data collection system of the installed production line
robotic assembly system (if such a system is available) to
implement the data collection template and provide an indication to
the user of the result of implementing the template. In response
thereto, the user may make a final approval of the template for use
with the production line robotic assembly system.
[1211] Referring to FIG. 149, an exemplary user interface for smart
band configuration of a system for data collection in an industrial
environment is depicted. The user interface 11200 may include an
industrial environment visualization portion 11202 in which may be
depicted one or more sensors, machines, and the like. Each sensor,
machine, or portion thereof (e.g., motor, compressor, and the like)
may be selectable as part of a smart-band configuration process.
Likewise, each sensor, machine or portion thereof may be visually
highlighted during the smart-band configuration process, such as in
response to user selection, or automated identification as being
part of a group of smart band sensors. The user interface may also
include a smart band selection portion 11204 or panel in which
smart band indicators, failure modes, and the like may be depicted
in selectable elements. User selection of a symptom, failure mode
and the like may cause corresponding components, sensors, machines,
and the like in the industrial visualization portion to be
highlighted. The user interface may also include a customization
panel 11206 in which attributes of a selected smart band, such as
acceptable ranges, frequency of monitoring and the like may be made
available for a user to adjust.
[1212] Clause 1. In embodiments, a system comprising: a user
interface comprising: a selectable graphical element that
facilitates selection of a representation of a component of an
industrial machine from an industrial environment in which a
plurality of sensors is deployed from which a data collection
system collects data for the system for which the user interface
enables interaction; and selectable graphical elements representing
a portion of the plurality of sensors that facilitate selection of
a sensors to form a data collection subset of sensors in the
industrial environment. 2. The system of clause 1, wherein
selection of sensors to form a data collection subset results in a
data collection template adapted to facilitate configuring the data
routing and collection system for collecting data from the data
collection subset of sensors. 3. The system of clause 1, wherein
the user interface comprises an expert system that analyzes a user
selection of a graphical element that facilitates selection of a
component and adjusts the selectable graphical elements
representing a portion of the plurality of sensors to activate only
sensors associated with a component associated with the selected
graphical element. 4. The system of clause 1, wherein the
selectable graphical element that facilitates selection of a
component of an industrial machine further facilitates presentation
of a plurality of data collection templates associated with the
component. 5. The system of clause 1, wherein the portion of the
plurality of sensors comprises a smart band group of sensors. 6.
The system of clause 5, wherein the smart band group of sensors
comprises sensors for a component of the industrial machine
selected by the selectable graphical element. 7. A system
comprising: an expert graphical user interface comprising
representations of a plurality of components of an industrial
machine from an industrial environment in which a plurality of
sensors is deployed from which a data collection system collects
data for the system for which the user interface enables
interaction, wherein at least one representation of the plurality
of components is selectable by a user in the user interface; a
database of industrial machine failure modes; and a database
searching facility that searches the database of failure modes for
modes that correspond to a user selection of a component of the
plurality of components. 8. The system of clause 7, comprising a
database of conditions associated with the failure modes. 9. The
system of clause 8, wherein the database of conditions includes a
list of sensors in the industrial environment associated with the
condition. 10. The system of clause 9, wherein the database
searching facility further searches the database of conditions for
sensors that correspond to at least one condition and indicates the
sensors in the graphical user interface. 11. The system of clause
7, wherein the user selection of a component of the plurality of
components causes a data collection template for configuring the
data routing and collection system to automatically collect data
from sensors associated with the selected component. 12. A method
comprising: presenting in an expert graphical user interface a list
of reliability measures of an industrial machine; facilitating user
selection of one reliability measure from the list; presenting a
representation of a smart band data collection template associated
with the selected reliability measure; and in response to a user
indication of acceptance of the smart band data collection
template, configuring a data routing and collection system to
collect data from a plurality of sensors in an industrial
environment in response to a data value from one of the plurality
of sensors being detected outside of an acceptable range of data
values. 13. The method of clause 12, wherein the reliability
measures include one or more of industry average data,
manufacturer's specifications, manufacturer's material
specifications, and manufacturer's recommendations. 14. The method
of clause 13, wherein include the manufacturer's specifications
include at least one of cycle count, working time, maintenance
recommendations, maintenance schedules, operational limits,
material limits, and warranty terms. 15. The method of clause 12,
wherein the reliability measures correlate to failures selected
from the list consisting of stress, vibration, heat, wear,
ultrasonic signature, and operational deflection shape effect. 16.
The method of clause 12, further comprising correlating sensors in
the industrial environment to manufacturer's specifications. 17.
The method of clause 16, wherein correlating comprises matching a
duty cycle specification to a sensor that detects revolutions of a
moving part. 18. The method of clause 16, wherein correlating
comprises matching a temperature specification with a thermal
sensor disposed to sense an ambient temperature proximal to the
industrial machine. 19. The method of clause 16, further comprising
dynamically setting the acceptable range of data values based on a
result of the correlating. 20. The method of clause 16, further
comprising automatically determining the one of the plurality of
sensors for detecting the data value outside of the acceptable
range based on a result of the correlating.
[1213] Back calculation, such as for determining possible root
causes of failures and the like, may benefit from a graphical
approach that facilitates visualizing an industrial environment,
machine, or portion thereof marked with indications of information
sources that may provide data such as sensors and the like related
to the failure. A failed part, such as a bearing, may be associated
with other parts, such as shaft, motor, and the like. Sensors for
monitoring conditions of the bearing and the associated parts may
provide information that could indicate a potential source of
failure. Such information may also be useful to suggest indicators,
such as changes in sensor output, to monitor or avoid the failure
in the future. A system that facilitates a graphical approach for
back-calculation may interact with sensor data collection and
analysis systems to at least partially automate aspects related to
data collection and processing determined from a back-calculation
process.
[1214] In embodiments, a system for data collection in an
industrial environment may include a user interface in which
portions of an industrial machine associated with a condition of
interest, such as a failure condition, are presented on an
electronic display along with sensor data types contributing to the
condition of interest, data collection points (e.g., sensors)
associated with the machine portions that monitor the data types, a
set of data from the data collection points that was collected and
used to determine the condition of interest, and an annotation of
sensors that delivered exceptional data, such as data that is out
of an acceptable range, and the like, that may have been used to
determine the condition of interest. The user interface may access
a description of the machine that facilitates determining and
visualizing related components, such as bearing, shafts, brakes,
rotors, motor housings, and the like that contribute to a function,
such as rotating a turbine. The user interface may also access a
data set that relates sensors disposed in and about the machine
with the components. Information in the data set may include
descriptions of the sensors, their function, a condition that each
senses, typical or acceptable ranges of values output from the
sensors, and the like. The information in the data set may also
identify a plurality of potential pathways in a system for data
collection in an industrial environment for sensor data to be
delivered to a data collector. The user interface may also access a
data set that may include data collection templates used to
configure a data collection system for collecting data from the
sensors to meet specific purposes (e.g., to collect data from
groups of sensors into a sensor data set suitable for determining a
condition of the machine, such as a degree of slippage of the shaft
relative to the motor, and the like).
[1215] In embodiments, a method of back-calculation for determining
candidate sources of data collection for data that contributes to a
condition of an industrial machine may include following routes of
data collection determined from a configuration and operational
template of a data collection system for collecting data from
sensors deployed in the industrial machine that was in place when
the contributing data was collected. A configuration and
operational template may describe signal path switching,
multiplexing, collection timing, and the like for data from a group
of sensors. The group of sensors may be local to a component, such
as a bearing, or more regionally distributed, such as sensors that
capture information about the bearing and its related components.
In embodiments, a data collection template may be configured for
collecting and processing data to detect a particular condition of
the industrial machine. Therefore, templates may be correlated to
conditions so that performing back-calculation of a condition of
interest can be guided by the correlated template. Data collected
based on the template may be examined and compared to acceptable
ranges of data for various sensors. Data that is outside of an
acceptable range may indicate potential root causes of an
unacceptable condition. In embodiments, a suspect source of data
collection may be determined from the candidate sources of data
collection based on a comparison of data collected from the
candidate data sources with an acceptable range of data collected
from each candidate data source. Visualizing these back-calculation
based signal paths, candidate sensors, and suspect data sources
provides a user with valuable insights into possible root causes of
failures and the like.
[1216] In embodiments, a method for back-calculation may include
visualizing route(s) of data that contribute to a fault condition
detected in an industrial environment by applying back-calculation
to determine sources of the contributed data with the visualizing
appearing as highlighted data paths in a visual representation of
the data collection system in the industrial machine. In
embodiments, determining sources of data may be based on a data
collection and processing template for the fault condition. The
template may include a configuration of a data collection system
when data from the determined sources was collected with the
system.
[1217] When failures occur, or conditions of a portion of a machine
in an industrial environment reach a critical point prior to
failure, such as may be detected during preventive maintenance and
the like, back-calculation may be useful in determining information
to gather that might help avoid the failure and/or improve system
performance--for example, by avoiding substantive degradation in
component operation. Visualizing data collection sources,
components related to a condition, algorithms that may determine
the potential onset of the condition and the like may facilitate
preparation of data collection templates for configuring data
sensing, routing, and collection resources in a system for data
collection in an industrial environment. In embodiments,
configuring a data collection template for a system for collecting
data in an industrial environment may be based on back-calculations
applied to machine failures that identify candidate conditions to
monitor for avoiding the machine failures. The resulting template
may identify sensors to monitor, sensor data collection path
configuration, frequency, and amount of data to collect, acceptable
levels of sensor data, and the like. With access to information
about the machine, such as which parts closely relate to others and
sensors that collected data from parts in the machine, a data
collection system configuration template may be automatically
generated when a target component is identified.
[1218] In embodiments, a user interface may include a graphical
display of data sources as a logical arrangement of sensors that
may contribute data to a calculation of a condition of a machine in
an industrial environment. A logical arrangement may be based on
sensor type, data collection template, condition, algorithm for
determining a condition, and the like. In an example, a user may
wish to view all temperature sensors that may contribute to a
condition, such as a failure of a part in an industrial
environment. A user interface may communicate with a database of
machine related information, such as parts that relate to a
condition, sensors for those parts, and types of those sensors to
determine the subset of sensors that measure temperature. The user
interface may highlight those sensors. The user interface may
activate selectable graphical elements for those sensors that, when
selected by the user, may present data associated with those
sensors, such as sensor type, ranges of data collected, acceptable
ranges, actual data values collected for a given condition, and the
like, such as in a pop-up panel or the like. Similar functionality
of the user interface may apply to physical arrangements of
sensors, such as all sensors associated with a motor, boring
machine cutting head, wind turbine, and the like.
[1219] In embodiments, third-parties, such as component
manufacturers, remote maintenance organizations and the like may
benefit from access to back-calculation visualization. Permitting
third parties to have access to back-calculation information, such
as sensors that contributed unacceptable data values to a
calculation of a condition, visualization of sensor positioning,
and the like may be an option that a user can exercise in a user
interface for a graphical approach to back-calculations as
described herein. A list of manufacturers of machines, sub-systems,
individual components, sensors, data collection systems, and the
like may be presented along with remote maintenance organizations,
and the like in a portion of a user interface. A user of the
interface may select one or more of these third-parties to grant
access to at least a portion of the available data and
visualizations. Selecting one or more of these third-parties may
also present statistical information about the party, such
occurrences and frequency of access to data to which the party is
granted access, request from the party for access, and the
like.
[1220] In embodiments, visualization of back-calculation analysis
may be combined with machine learning so that back-calculations and
their visualizations may be used to learn potential new diagnoses
for conditions, such as failure conditions, to learn new conditions
to monitor, and the like. A user may interact with the user
interface to provide the machine learning techniques feedback to
improve results, such as indicating a success or failure of an
attempt to prevent failures through specific data collection and
processing solutions (e.g., templates), and the like.
[1221] In embodiments, methods and systems of back-calculation of
data collected with a system for data collection in an industrial
environment may be applied to concrete pouring equipment in a
construction site application. Concrete pouring equipment may
comprise several active components including mixers that may
include water and aggregate supply systems, mixing control systems,
mixing motors, directional controllers, concrete sensors and the
like, concrete pumps, delivery systems, flow control as well as
on/off controls, and the like. Back-calculation of failure or other
conditions of active or passive components of a concrete pouring
equipment may benefit from visualization of the equipment, its
components, sensors, and other points where data is collected
(e.g., controllers and the like). Visualizing data/conditions
collected from sensors associated with concrete pumps and the like
when performing back-calculation of a flow rate failure condition
may inform the user of a conditions of the pump that may contribute
to the flow rate failure. Flow rate may decrease contemporaneously
with an increase in temperature of the pump. This may be visualized
by, for example, presenting the flow rate sensor data and the pump
temperature sensor data in the user interface. This correlation may
be noted by an expert system or by a user observing the
visualization and corrective action may be taken.
[1222] In embodiments, methods and systems of back-calculation of
data collected with a system for data collection in an industrial
environment may be applied to digging and extraction systems in a
mining application. Digging and extraction systems may comprise
several active sub-systems including cutting heads, pneumatic
drills, jack hammers, excavators, transport systems, and the like.
Back-calculation of failure or other conditions of active or
passive components of digging and extraction systems may benefit
from visualization of the equipment, its components, sensors, and
other points where data is collected (e.g., controllers and the
like). Visualizing data/conditions collected from sensors
associated with pneumatic drills and the like when performing
back-calculation of a pneumatic line failure condition may inform
the user of a conditions of the drill that may contribute to the
line failure. Line pressure may increase contemporaneously with a
change of a condition of the drill. This may be visualized by, for
example, presenting the line pressure sensor data and data from
sensors associated with the drill in the user interface. This
correlation may be noted by an expert system or by a user observing
the visualization and corrective action may be taken.
[1223] In embodiments, methods and systems of back-calculation of
data collected with a system for data collection in an industrial
environment may be applied to cooling towers in an oil and gas
production environment. Cooling towers may comprise several active
components including feedwater systems, pumps, valves,
temperature-controlled operation, storage systems, mixing systems,
and the like. Back-calculation of failure or other conditions of
active or passive components of cooling towers may benefit from
visualization of the equipment, its components, sensors and other
points where data is collected (e.g., controllers and the like).
Visualizing data/conditions collected from sensors associated with
the cooling towers and the like when performing back-calculation of
a circulation pump failure condition may inform the user of a
conditions of the cooling towers that may contribute to the pump
failure. Temperature of the feedwater may increase
contemporaneously with a decrease in output of the circulation
pump. This may be visualized by, for example, presenting the feed
water temperature sensor data and the pump output rate sensor data
in the user interface. This correlation may be noted by an expert
system or by a user observing the visualization and corrective
action may be taken.
[1224] In embodiments, methods and systems of back-calculation of
data collected with a system for data collection in an industrial
environment may be applied to circulation water systems in a power
generation application. Circulation water systems may comprise
several active components including, pumps, storage systems, water
coolers, and the like. Back-calculation of failure or other
conditions of active or passive components of circulation water
systems may benefit from visualization of the equipment, its
components, sensors and other points where data is collected (e.g.,
controllers and the like). Visualizing data/conditions collected
from sensors associated with water coolers and the like when
performing back-calculation of a circulation water temperature
failure condition may inform the user of a conditions of the cooler
that may contribute to the temperature condition failure.
Circulation temperature may increase contemporaneously with an
increase of core water cooler temperature. This may be visualized
by, for example, presenting the circulation water temperature
sensor data and the water cooler temperature sensor data in the
user interface. This correlation may be noted by an expert system
or by a user observing the visualization and corrective action may
be taken.
[1225] Referring to FIG. 150 a graphical approach 11300 for
back-calculation is depicted. Components of an industrial
environment may be depicted in a map of the environment 11302.
Components that may have a history of failure (with this
installation or others) may be highlighted. In response to a
selection of one of these components (such as by a user making the
selection), related components and sensors for the selected part
and related components may be highlighted, including signal routing
paths for the data from their relevant sensors to a data collector.
Additional highlighting may be added to sensors from which
unacceptable data has been collected, thereby indicating potential
root causes of a failure of the selected part. The relationships
among the parts may be based at least in part on machine
configuration metadata. The relationship between specific sensors
and the failure condition may be based at least in part on a data
collection template associated with the part and/or associated with
the failure condition.
[1226] Clause 1. In embodiments, a system comprising: a user
interface of a system adapted to collect data in an industrial
environment; the user interface comprising: a plurality of
graphical elements representing mechanical portions of an
industrial machine, wherein the plurality of graphical elements is
associated with a condition of interest generated by a processor
executing a data analysis algorithm; a plurality of graphical
elements representing data collectors in a system adapted for
collecting data in an industrial environment that collected data
used in the data analysis algorithm; and a plurality of graphical
elements representing sensors used to capture the data used in the
data analysis algorithm, wherein graphical elements for sensors
that provided data that was outside of an acceptable range of data
values are indicated through a visual highlight in the user
interface. 2. The system of clause 1, wherein the condition of
interest is selected from a list of conditions of interest
presented in the user interface. 3. The system of clause 1, wherein
the condition of interest is a mechanical failure of at least one
of the mechanical portions of the industrial machine. 4. The system
of clause 1, wherein the mechanical portions comprise at least one
of a bearing, shaft, rotor, housing, and linkage of the industrial
machine. 5. The system of clause 1, wherein the acceptable range of
data values is available for each sensor. 6. The system of clause
1, further comprising highlighting data collectors that collected
the data that was outside of the acceptable range of data values.
7. The system of clause 1, further comprising a data collection
system configuration template that facilitates configuring the data
collection system to collect the data for calculating the condition
of interest. 8. A method of determining candidate sources of a
condition of interest comprising: identifying a data collection
template for configuring data routing and collection resources in a
system adapted to collect data in an industrial environment,
wherein the template was used to collect data that contributed to a
calculation of the condition of interest; determining paths from
data collectors for the collected data to sensors that produced the
collected data by analyzing the data collection template; comparing
data collected by the sensors with acceptable ranges of data values
for data collected by the sensors; and highlighting, in an
electronic user interface that depicts the industrial environment
and at least one of the sensors, at least one sensor that produced
data that contributed to the calculation of the condition of
interest that is outside of the acceptable range of data for that
sensor. 9. The method of clause 8, wherein the condition of
interest is a failure condition. 10. The method of clause 8,
wherein the data collection template comprises configuration
information for at least one of an analog crosspoint switch, a
multiplexer, a hierarchical multiplexer, a sensor, a collector, and
a data storage facility of the system adapted to collect data in
the industrial environment. 11. The method of clause 8, wherein the
highlighting in the industrial environment comprises highlighting
he at least one sensor, and at least one route of data from the
sensor to a data collector of the system for data collection in the
industrial environment. 12. The method of clause 8, wherein
comparing data collected by the sensors with acceptable ranges of
data values comprises comparing data collected by each sensor with
an acceptable range of data values that is specific to each sensor.
13. The method of clause 8, wherein the calculation of the
condition of interest comprises calculating a trend of data from at
least one sensor. 14. The method of clause 8, wherein the
acceptable range of values comprises a trend of data values. 15. A
method of visualizing routes of data that contribute to a condition
of interest that is detected in an industrial environment, the
method comprising: applying back calculation to the condition of
interest to determine a data collection system configuration
template associated with the condition of interest; analyzing the
template to determine a configuration of the data collection system
for collecting data for detecting the condition of interest;
presenting, in an electronic user interface, a map of the data
collection configured by the template; and highlighting, in the
electronic user interface, routes in the data collection system
that reflect paths of data from at least one sensor to at least one
data collector for data that contributes to calculating the
condition of interest. 16. The method of clause 15 wherein the data
collection system configuration template comprises configuration
information for at least one resource deployed in the data
collection system selected from the list consisting of an analog
crosspoint switch, a multiplexer, a hierarchical multiplexer, a
data collector, and a sensor. 17. The method of clause 15, further
comprising generating a target diagnosis for the condition of
interest by applying machine learning to the back calculation. 18.
The method of clause 15, further comprising highlighting in the
electronic user interface, sensors that produce data used in
calculating the condition of interest that is outside of an
acceptable range of data values for the sensor. 19. The method of
clause 15, wherein the condition of interest is selected from a
list of conditions of interest presented in the user interface. 20.
The system of clause 15, wherein the condition of interest is a
mechanical failure of at least one mechanical portion of the
industrial environment. 21. The system of clause 15, wherein the
mechanical portions comprise at least one of a bearing, shaft,
rotor, housing, and linkage of the industrial environment.
[1227] In embodiments, a system for data collection in an
industrial environment may route data from a plurality of sensors
in the industrial environment to wearable haptic stimulators that
present the data from the sensors as human detectable stimuli
including at least one of tactile, vibration, heat, sound, and
force. In embodiments, the haptic stimulus represents an effect on
the machine resulting from the sensed data. In embodiments, a
bending effect may be presented as bending a finger of a haptic
glove. In embodiments, a vibrating effect may be presented as
vibrating a haptic arm band. In embodiments, a heating effect may
be presented as an increase in temperature of a haptic wrist band.
In embodiments, an electrical effect (e.g., over voltage, current,
and others) may be presented as a change in sound of a phatic audio
system.
[1228] In embodiments, an industrial machine operator haptic user
interface may be adapted to provide haptic stimuli to the operator
that is responsive to the operator's control of the machine,
wherein the stimuli indicate an impact on the machine as a result
of the operator's control and interaction with objects in the
environment as a result thereof. In embodiments, sensed conditions
of the machine that exceed an acceptable range may be presented to
the operator through the haptic user interface. In embodiments, the
sensed conditions of the machine that are within an acceptable
range may not be presented to the operator through the haptic user
interface. In embodiments, the sensed conditions of the machine
that are within an acceptable range may presented as natural
language representations of confirmation of the operator control.
In embodiments, at least a portion of the haptic user interface is
worn by the operator. In embodiments, a wearable haptic user
interface device may include force exerting devices along the outer
legs of a device operator's uniform. When a vehicle that the
operator is controlling approaches an obstacle along a lateral side
of the vehicle, an inflatable bellows may be inflated, exerting
pressure against the leg of the operator closest to the side of the
vehicle approaching the obstacle. The bellows may continue to be
inflated, thereby exerting additional pressure on the operator's
leg that is consistent with the proximity of the obstacle. The
pressure may be pulsed when contact with the obstacle is imminent.
In another example, an arm band of an operator may vibrate in
coordination with vibration being experienced by a portion of the
vehicle that the operator is controlling. These are merely examples
and not intended to be limiting or restrictive of the ways in which
a wearable haptic feedback user device may be controlled to
indicate conditions that are sensed by a system for data collection
in an industrial environment.
[1229] In embodiments, a haptic user interface safety system worn
by a user in an industrial environment may be adapted to indicate
proximity to the user of equipment in the environment by
stimulating a portion of the user with at least one of pressure,
heat, impact, electrical stimuli and the like, the portion of the
user being stimulated may be closest to the equipment. In
embodiments, at least one of the type, strength, duration, and
frequency of the stimuli is indicative of a risk of injury to the
user.
[1230] In embodiments, a wearable haptic user interface device,
that may be worn by a user in an industrial environment, may
broadcast its location and related information upon detection of an
alert condition in the industrial environment. The alert condition
may be proximal to the user wearing the device, or not proximal but
related to the user wearing the device. A user may be an emergency
responder, so the detection of a situation requiring an emergency
responded, the user's haptic device may broadcast the user's
location to facilitate rapid access to the user or by the user to
the emergency location. In embodiments, an alert condition may be
determined from monitoring industrial machine sensors may be
presented to the user as haptic stimuli, with the severity of the
alert corresponding to a degree of stimuli. In embodiments, the
degree of stimuli may be based on the severity of the alert, the
corresponding stimuli may continue, be repeated, or escalate,
optionally including activating multiple stimuli concurrently, send
alerts to additional haptic users, and the like until an acceptable
response is detected, e.g., through the haptic UI. The wearable
haptic user device may be adapted to communicate with other haptic
user devices to facilitate detecting the acceptable response.
[1231] In embodiments, a wearable haptic user interface for use in
an industrial environment may include gloves, rings, wrist bands,
watches, arm bands, head gear, belts, necklaces, shirts (e.g.,
uniform shirt), foot wear, pants, ear protectors, safety glasses,
vests, overalls, coveralls, and any other article of clothing or
accessory that can be adapted to provide haptic stimuli.
[1232] In embodiments, wearable haptic device stimuli may be
correlated to a sensor in an industrial environment. Non-limiting
examples include a vibration of a wearable haptic device in
response to vibration detected in an industrial environment;
increasing or decreasing the temperature of a wearable haptic
device in response to a detected temperature in an industrial
environment; producing sound that changes in pitch responsively to
changes in a sensed electrical signal, and the like. In
embodiments, a severity of wearable haptic device stimuli may
correlate to an aspect of a sensed condition in the industrial
environment. Non-limiting examples include moderate or short-term
vibration for a low degree of sensed vibration; strong or long-term
vibration stimulation for an increase in sensed vibration;
aggressive, pulsed, and/or multi-mode stimulation for a high amount
of sensed vibration. Wearable haptic device stimuli may also
include lighting (e.g., flashing, color changes, and the like),
sound, odor, tactile output, motion of the haptic device (e.g.,
inflating/deflating a balloon, extension/retraction of an
articulated segment, and the like), force/impact, and the like.
[1233] In embodiments, a system for data collection in an
industrial environment may interface with wearable haptic feedback
user devices to relay data collected from fuel handling systems in
a power generation application to the user via haptic stimulation.
Fuel handling for power generation may include solid fuels, such as
woodchips, stumps, forest residue, sticks, energy willow, peat,
pellets, bark, straw, agro biomass, coal, and solid recovery fuel.
Handling systems may include receiving stations that may also
sample the fuel, preparation stations that may crush or chip
wood-based fuel or shred waste-based fuel. Fuel handling systems
may include storage and conveying systems, feed and ash removal
systems and the like. Wearable haptic user interface devices may be
used with fuel handling systems by providing an operator feedback
on conditions in the handling environment that the user is
otherwise isolated from. Sensors may detect operational aspects of
a solid fuel feed screw system. Conditions like screw rotational
rate, weight of the fuel, type of fuel, and the like may be
converted into haptic stimuli to a user while allowing the user to
use his hands and provide his attention to operate the fuel feed
system.
[1234] In embodiments, a system for data collection in an
industrial environment may interface with wearable haptic feedback
user devices to relay data collected from suspension systems of a
truck and/or vehicle application to the user via haptic
stimulation. Haptic simulation may be correlated with conditions
being sensed by the vehicle suspension system. In embodiments, road
roughness may be detected and converted into vibration-like stimuli
of a wearable haptic arm band. In embodiments, suspension forces
(contraction and rebound) may be converted into stimuli that
present a scaled down version of the forces to the user through a
wearable haptic vest.
[1235] In embodiments, a system for data collection in an
industrial environment may interface with wearable haptic feedback
user devices to relay data collected from hydroponic systems in an
agriculture application to the user via haptic stimulation. In
embodiments, sensors in hydroponic systems, such as temperature,
humidity, water level, plant size, carbon dioxide/oxygen levels,
and the like may be converted to wearable device haptic stimuli. As
an operator wearing haptic feedback clothing walks through a
hydroponic agriculture facility, sensors proximal to the operator
may signal to the haptic feedback clothing relevant information,
such as temperature or a measure of actual temperature versus
desired temperature that the haptic clothing may convert into
haptic stimuli. In an example, a wrist band may include a thermal
stimulator that can change temperature quickly to track temperature
data or a derivative thereof from sensors in the agriculture
environment. As a user walks through the facility, the haptic
feedback wristband may change temperature to indicate a degree to
which proximal temperatures are complying with expected
temperatures.
[1236] In embodiments, a system for data collection in an
industrial environment may interface with wearable haptic feedback
user devices to relay data collected from robotic positioning
systems in an automated production line application to the user via
haptic stimulation Haptic feedback may include receiving a
positioning system indicator of accuracy and converting it to an
audible signal when the accuracy is acceptable, and another type of
stimuli when the accuracy is not acceptable.
[1237] Referring to FIG. 151, a wearable haptic user interface
device for providing haptic stimuli to a user that is responsive to
data collected in an industrial environment by a system adapted to
collect data in the industrial environment is depicted. A system
for data collection 11402 in an industrial environment 11400 may
include a plurality of sensors. Data from those sensors may be
collected and analyzed by a computing system. A result of the
analysis may be communicated wirelessly to one or more wearable
haptic feedback stimulators 11404 worn by a user associated with
the industrial environment. The wearable haptic feedback
stimulators may interpret the result, convert it into a form of
stimuli based on a haptic stimuli-to-sensed condition mapping, and
produce the stimuli.
[1238] Clause 1. In embodiments, a system for data collection in an
industrial environment, comprising: a plurality of wearable haptic
stimulators that produce stimuli selected from the list of stimuli
consisting of tactile, vibration, heat, sound, force, odor, and
motion; a plurality of sensors deployed in the industrial
environment to sense conditions in the environment; a processor
logically disposed between the plurality of sensors and the
wearable haptic stimulators, the processor receiving data from the
sensors representative of the sensed condition, determining at
least one haptic stimulation that corresponds to the received data,
and sending at least one signal for instructing the wearable haptic
stimulators to produce the at least one stimulation 2. The system
of clause 1, wherein the haptic stimulation represents an effect on
a machine in the industrial environment resulting from the
condition. 3. The system of clause 2, wherein a bending effect is
presented as bending a haptic device. 4. The system of clause 2,
wherein a vibrating effect is presented as vibrating a haptic
device. 5. The system of clause 2, wherein a heating effect is
presented as an increase in temperature of a haptic device. 6. The
system of clause 2, wherein an electrical effect is presented as a
change in sound produced by a haptic device. 7. The system of
clause 2, wherein at least one of the plurality of wearable haptic
stimulators are selected from the list consisting of a glove, ring,
wrist band, wrist watch, arm band, head gear, belt, necklace,
shirt, foot wear, pants, overalls, coveralls, and safety goggles.
8. The system of clause 2, wherein the at least one signal
comprises an alert of a condition of interest in the industrial
environment. 9. The system of clause 8, wherein the at least one
stimulation produced in response to the alert signal is repeated by
at least one of the plurality of wearable haptic stimulators until
an acceptable response is detected. 10. An industrial machine
operator haptic user interface that is adapted to provide the
operator haptic stimuli responsive to the operator's control of the
machine based on at least one sensed condition of the machine that
indicates an impact on the machine as a result of the operator's
control and interaction with objects in the environment as a result
thereof. 11. The user interface of clause 10, wherein a sensed
condition of the machine that exceeds an acceptable range of data
values for the condition is presented to the operator through the
haptic user interface. 12. The user interface of clause 10, wherein
a sensed condition of the machine that is within an acceptable
range of data values for the condition is presented as natural
language representations of confirmation of the operator control
via an audio haptic stimulator. 13. The user interface of clause
10, wherein at least a portion of the haptic user interface is worn
by the operator. 14. The system of clause 10, wherein a vibrating
sensed condition is presented as vibrating stimulation by the
haptic user interface. 15. The system of clause 10, wherein a
temperature-based sensed condition is presented as heat stimulation
by the haptic user interface. 16. A haptic user interface safety
system worn by a user in an industrial environment, wherein the
interface is adapted to indicate proximity to the user of equipment
in the environment by haptic stimulation via a portion of the
haptic user interface that is closest to the equipment, wherein at
least one of the type, strength, duration, and frequency of the
stimulation is indicative of a risk of injury to the user. 17. The
haptic user interface of clause 16, wherein the haptic stimulation
is selected from a list consisting of pressure, heat, impact, and
electrical stimulation. 18. The haptic user interface of clause 16
wherein the haptic user interface further comprises a wireless
transmitter that broadcasts a location of the user. 19. The haptic
user interface of clause 18, wherein the wireless transmitter
broadcasts a location of the user in response to indicating
proximity of the user to the equipment. 20. The haptic user
interface of clause 16, wherein the proximity to the user of
equipment in the environment is based on sensor data provided to
the haptic user interface from a system adapted to collect data in
an industrial environment, wherein the system is adapted based on a
data collection template associated with a user safety condition in
the industrial environment.
[1239] In embodiments, a system for data collection in an
industrial environment may facilitate presenting a graphical
element indicative of industrial machine sensed data on an
augmented reality (AR) display. The graphical element may be
adapted to represent a position of the sensed data on a scale of
acceptable values of the sensed data. The graphical element may be
positioned proximal to a sensor detected in the field of view being
augmented that captured the sensed data in the AR display. The
graphical element may be a color and the scale may be a color scale
ranging from cool colors (e.g., greens, blues) to hot colors (e.g.,
yellow, red) and the like. Cool colors may represent data values
closer to the midpoint of the acceptable range and the hot colors
representing data values close to or outside of a maximum or
minimum value of the range.
[1240] In embodiments, a system for data collection in an
industrial environment may present, in an AR display, data being
collected from a plurality of sensors in the industrial environment
as one of a plurality graphical effects (e.g., colors in a range of
colors) that correlate the data being collected from each sensor to
a scale of values within an acceptable range compared to values
outside of the acceptable range. In embodiments, the plurality of
graphical effects may overlay a view of the industrial environment
and placement of the plurality of graphical effects may correspond
to locations in the view of the environment at which a sensor is
located that is producing the corresponding sensor data. In
embodiments, a first set of graphical effects (e.g., hot colors)
represent components for which multiple sensors indicate values
outside acceptable ranges.
[1241] In embodiments, a system for data collection in an
industrial environment may facilitate presenting, in an AR display
information being collected by sensors in the industrial
environment as a heat map overlaying a visualization of the
environment so that regions of the environment with sensor data
suggestive of a greater potential of failure are overlaid with a
graphic effect that is different than regions of the environment
with sensor data suggestive of a lesser potential of failure. In
embodiments, the heat map is based on data currently being sensed.
In embodiments, the heat map is based on data from prior failures.
In embodiments, the heat map is based on changes in data from an
earlier period, such as data that suggest an increased likelihood
of machine failure. In embodiments, the heat map is based on a
preventive maintenance plan and a record of preventive maintenance
in the industrial environment.
[1242] In embodiments, a system for data collection in an
industrial environment may facilitate presenting information being
collected by sensors in the industrial environment as a heat map
overlaying a view of the environment, such as a live view as may be
presented in an AR display. Such a system may include presenting an
overlay that facilitates a call to action, wherein the overlay is
associated with a region of the heat map. The overlay may comprise
a visual effect of a part or subsystem of the environment on which
the action is to be performed. In embodiments, the action to be
performed is maintenance related and may be part-specific.
[1243] In embodiments, a system for data collection in an
industrial environment may facilitate updating, in an AR view of a
portion of the environment, a heat map of aspects of the industrial
environment based on a change to operating instructions for at
least one aspect of a machine in the industrial environment. The
heat map may represent compliance with operational limits for
portions of machines in the industrial environment. In embodiments,
the heat map may represent a likelihood of component failure as a
result of the change to operation instructions.
[1244] In embodiments, a system for data collection in an
industrial environment may facilitate presenting, as a heat map in
an AR view of a portion of the environment, a degree or measure of
coverage of sensors in the industrial environment for a data
collection template that identifies select sensors in the
industrial environment for a data collection activity.
[1245] In embodiments, a system for data collection in an
industrial environment may facilitate displaying a heat map
overlaying a view, such as a live view, of an industrial
environment of failure-related data for various portions of the
environment. The failure-related data may comprise a difference
between an actual failure rate of the various portions and another
failure rate. Another failure rate may be a rate of failure of
comparable portions elsewhere in the environment, and/or average
failure rate of comparable portions across a plurality of
environments, such as an industry average, manufacturer failure
rate estimate, and the like.
[1246] In embodiments, a system for data collection in an
industrial environment may facilitate displaying a heat map related
to data collected from robotic arms and hands for production line
robotic handling in an augmented reality view of a portion of the
environment. A heat map related to data collected from robotic arms
and hands may represent data from sensors disposed in--for example,
the fingers of a robotic hand. Sensor may collect data, such as
applied pressure when pinching an object, resistance (e.g.,
responsive to a robotic touch) of an object, multi-axis forces
presented to the finger as it performs an operation, such as
holding a tool and the like, temperature of the object, total
movement of the finger from initial point of contact until a
resistance threshold is met, and other hand position/use
conditions. Heat maps of this data may be presented in an augmented
reality view of a robotic production environment so that a user may
make a visual assessment of, for example, how the relative
positioning of the robotic fingers impacts the object being
handled.
[1247] In embodiments, a system for data collection in an
industrial environment may facilitate displaying a heat map related
to data collected from linear bearings for production line robotic
handling in an augmented reality view of a portion of the
environment. Linear bearings, as with most bearings, may not be
visible while in use. However, assessing their operation may
benefit from representing data from sensors that capture
information about the bearings while in use in an augmented reality
display. In embodiments, sensors may be placed to detect forces
being placed on portions of the bearings by the rotating member or
elements that the bearings support. These forces may be presented
as heat maps that correspond to relative forces, on a visualization
of the bearings in an augmented reality view of a robot handling
machine that uses linear bearings.
[1248] In embodiments, a system for data collection in an
industrial environment may facilitate displaying a heat map related
to data collected from boring machinery for mining in an augmented
reality view of a portion of the environment. Boring machinery, and
in particular multi-tip circular boring heads may experience a
range of rock formations at the same time. Sensors may be placed
proximal to each boring tip that may detect forces experienced by
the tips. The data may be collected by a system adapted to collect
data in an industrial environment and provided to an augmented
reality system that may display the data as heat maps or the like
in a view of the boring machine.
[1249] Referring to FIG. 152, an augmented reality display of heat
maps based on data collected in an industrial environment by a
system adapted to collect data in the environment is depicted. An
augmented reality view of an industrial environment 11500 may
include heat maps 11502 that depict data received from or derived
from data received from sensors 11504 in the industrial
environment. Sensor data may be captured and processed by a system
adapted for data collection and analysis in an industrial
environment. The data may be converted into a form that is suitable
for use in an augmented reality system for displaying heat maps.
The heat maps 11502 may be aligned in the augmented reality view
with a sensor from which the underlying data was sourced.
[1250] Clause 1. In embodiments, an augmented reality (AR) system
in which industrial machine sensed data is presented in a view of
the industrial machine as heat maps of data collected from sensors
in the view, wherein the heat maps are positioned proximal to a
sensor capturing the sensed data that is visible in the AR display.
2. The system of clause 1, wherein the heat maps are based on a
comparison of real time data collected from sensors with an
acceptable range of values for the data. 3. The system of clause 1,
wherein the heat maps are based on trends of sensed data. 4. The
system of clause 1, wherein the heat maps represent a measure of
coverage of sensors in the industrial environment in response to a
condition of interest that is calculated from data collected by
sensors in the industrial environment. 5. The system of clause 1,
wherein the heat maps of data collected from sensors in the view is
based on data collected by a system adapted to collect data in the
industrial environment by routing data from a plurality of sensors
to a plurality of data collectors via at least one of an analog
crosspoint switch, a multiplexer, and a hierarchical multiplexer.
6. The system of clause 1, wherein the heat maps present different
collected data values as different colors. 7. The system of clause
1, wherein data collected from a plurality of sensors is combined
to produce a heat map. 8. A system for data collection in an
industrial environment, comprising: an augmented reality display
that presents data being collected from a plurality of sensors in
the industrial environment as one of a plurality of colors, wherein
the colors correlate the data being collected from each sensor to a
color scale with cool colors mapping to values of the data within
an acceptable range and hot colors mapping to values of the data
outside of the acceptable range, wherein the plurality of colors
overlay a view of the industrial environment and placement of the
plurality of colors corresponds to locations in the view of the
environment at which a sensor is located that is producing the
corresponding sensor data. 9. The system of clause 8, wherein hot
colors represent components for which multiple sensors indicate
values outside typical ranges. 10. The system of clause 8, wherein
the plurality of colors is based on a comparison of real time data
collected from sensors with an acceptable range of values for the
data. 11. The system of clause 8, wherein the plurality of colors
is based on trends of sensed data. 12. The system of clause 8,
wherein the plurality of colors represents a measure of coverage of
sensors in the industrial environment in response to a condition of
interest that is calculated from data collected by sensors in the
industrial environment. 13. A method comprising, presenting
information being collected by sensors in an industrial environment
as a heat map overlaying a view of the environment so that regions
of the environment with sensor data suggestive of a greater
potential of failure are overlaid with a heat map that is different
than regions of the environment with sensor data suggestive of a
lesser potential of failure. 14. The method of clause 13, wherein
the heat map is based on data currently being sensed. 15. The
method of clause 13, wherein the heat map is based on data from
prior failure data. 16. The method of clause 13, wherein the heat
map is based on changes in data from an earlier period that suggest
an increased likelihood of machine failure. 17. The method of
clause 13, wherein the heat map is based on a preventive
maintenance plan and a record of preventive maintenance in the
industrial environment. 18. The method of clause 13, wherein the
heat map represents an actual failure rate versus a reference
failure rate. 19. The method of clause 18, wherein the reference
failure rate is an industry average failure rate. 20. The method of
clause 18, wherein the reference failure rate is a manufacturer's
failure rate estimate.
[1251] In embodiments, a system for data collection and
visualization thereof in an industrial environment may include an
augmented reality and/or virtual reality (AR/VR) display in which
data values output by sensors disposed in a field of view in the
AR/VR display are displayed with visual attributes that indicate a
degree of compliance of the data to an acceptable range or values
for the sensed data. In embodiments, the visual attributes may
provide near real-time portrayal of trends of the sensed data
and/or of derivatives thereof. In embodiments, the visual
attributes may be the actual data being captured, or the derived
data, such as a trend of the data and the like.
[1252] In embodiments, a system for data collection and
visualization thereof in an industrial environment may include an
AR/VR display in which trends of data values output by sensors
disposed in a field of view in the AR/VR are displayed with visual
attributes that indicate a degree of severity of the trend. In
embodiments, other data or analysis that could be displayed may
include: data from sensors that exceed an acceptable range, data
from sensors that are part of a smart band selected by the user,
data from sensors that are monitored for triggering a smart band
collection action, data from sensors that sense an aspect of the
environment that meets preventive maintenance criteria, such as a
PM action is upcoming soon, a PM action was recently performed or
is overdue for PM. Other data for such AR/VR visualization may
include data from sensors for which an acceptable range has
recently been changed, expanded, narrowed and the like. Other data
for such AR/VR visualization that may be particularly useful for an
operator of an industrial machine (digging, drilling, and the like)
may include analysis of data from sensors, such as for example
impact on an operating element (torque, force, strain, and the
like).
[1253] In embodiments, a system for data collection and
visualization thereof in an industrial environment that may include
presentation of visual attributes that represent collected data in
an AR/VR environment may do so for pumps in a mining application.
Mining application pumps may provide water and remove liquefied
waste from a mining site. Pump performance may be monitored by
sensors detecting pump motors, regulators, flow meters, and the
like. Pump performance monitoring data may be collected and
presented as a set of visual attributes in an augmented reality
display. In an example, pump motor power consumption, efficiency,
and the like may be displayed proximal to a pump viewed through an
augmented reality display.
[1254] In embodiments, a system for data collection and
visualization thereof in an industrial environment that may include
presentation of visual attributes that represent collected data in
an AR/VR environment may do so for energy storage in a power
generation application. Power generation energy storage may be
monitored with sensors that capture data related to storage and use
of stored energy. Information such as utilization of individual
energy storage cells, energy storage rate (e.g., battery charging
and the like), stored energy consumption rate (e.g., KWH being
supplied by an energy storage system), storage cell status, and the
like may be captured and converted into augmented reality viewable
attributes that may be presented in an augmented reality view of an
energy storage system.
[1255] In embodiments, a system for data collection and
visualization thereof in an industrial environment that may include
presentation of visual attributes that represent collected data in
an AR/VR environment may do so for feed water systems in a power
generation application. Sensors may be disposed in an industrial
environment, such as power generation for collecting data about
feed water systems. Data from those sensors may be captured and
processed by the system for data collection. Results of this
processing may include trends of the data, such as feed water
cooling rates, flow rates, pressure and the like. These trends may
be presented on an augmented reality view of a feed water system by
applying a map of sensors with physical elements visible in the
view and then retrieving data from the mapped sensors. The
retrieved data (and derivatives thereof) may be presented in the
augmented reality view of the feed water system.
[1256] Referring to FIG. 153, an augmented reality display 11600
comprising real time data 11602 overlaying a view of an industrial
environment is depicted. Sensors 11604 in the environment may be
recognized by the augmented reality system, such as by first
detecting an industrial machine, system, or part thereof with which
the sensors are associated. Data from the sensors 11604 may be
retrieved from a data repository, processed into trends, and
presented in the augmented reality view 11600 proximal to the
sensors from which the data originates
[1257] Clause 1 In embodiments, a system for data collection and
visualization thereof in an industrial environment in which data
values output by sensors disposed in a field of view in an
electronic display are displayed in the electronic display with
visual attributes that indicate a degree of compliance of the data
to an acceptable range or values for the sensed data. 2. The system
of clause 1, wherein the view in the electronic display is a view
in an augmented reality display of the industrial environment. 3.
The system of clause 1, wherein the visual attributes are
indicative of a trend of the sensed data over time relative to the
acceptable range. 4. The system of clause 1, wherein the data
values are disposed in the electronic display proximal to the
sensors from which the data values are output. 5. The system of
clause 1, wherein the visual attributes further comprise an
indication of a smart band set of sensors associated with the
sensor from which the data values are output. 6. A system for data
collection and visualization thereof in an industrial environment
in which data values output by select sensors disposed in an
augmented reality view of the industrial environment are displayed
with visual attributes that indicate a degree of compliance of the
data to an acceptable range or values for the sensed data. 7. The
system of clause 6, wherein the sensors are selected based on a
data collection template that facilitates configuring sensor data
routing resources in the system. 8. The system of clause 7, wherein
the select sensors are indicated in the template as part of a group
of smart band sensors. 9. The system of clause 7, wherein the
select sensors are sensors that are monitored for triggering a
smart band data collection action. 10. The system of clause 6,
wherein the select sensors are sensors that sense an aspect of the
environment associated with preventive maintenance criteria. 11.
The system of clause 6, wherein the visual attributes further
indicate if the acceptable range has been expanded or narrowed
within the past 72 hours. 12. A system for data collection and
visualization thereof in an industrial environment in which trends
of data values output by select sensors disposed in a field of view
of the industrial environment depicted in an augmented reality
display are displayed with visual attributes that indicate a degree
of severity of the trend. 13. The system of clause 12, wherein
sensors are selected when data from the sensors exceed an
acceptable range of values. 14. The system of clause 14, wherein
sensors are selected based on the sensors being part of a smart
band group of sensors. 15. The system of clause 12, wherein the
visual attributes further indicate a compliance of the trend with
an acceptable range of data values. 16. The system of clause 12,
wherein the system for data collection is adapted to route data
from the select sensors to a controller of the augmented reality
display based on a data collection template that facilitates
configuring routing resources of the system for data collection.
17. The system of clause 12, wherein the sensors are selected in
response to the sensor data being configured in a smart band data
collection template as an indication for triggering a smart band
data collection action. 18. The system of clause 12, wherein the
sensors are selected in response to preventive maintenance
criteria. 19. The system of clause 18, wherein the preventive
maintenance criteria are selected from the list consisting of a
preventive maintenance action is scheduled, a preventive
maintenance action has been completed in the last 72 hours, a
preventive maintenance action is overdue.
[1258] FIG. 155 shows a system for data collection in an industrial
environment having a self-sufficient data acquisition box for
capturing and analyzing data in an industrial environment including
sensor inputs 11700, 11702, 11704, 11706 that connect to a data
circuit 11708 for analyzing the sensor inputs, a network
communication interface 11712, a network control circuit 11710 for
sending and receiving information related to the sensor inputs to
an external system and a data filter circuit configured to
dynamically adjust what portion of the information is sent based on
instructions received over the network communication interface. A
variety of sensor inputs X connect to the data circuit Y. The data
circuit intercommunicates with a network control circuit, which is
connected to one or more network interfaces. These interfaces may
include wired interfaces or wireless interfaces, communicating via
a star, multi-hop, peer-to-peer, hub-and-spoke, mesh, ring,
hierarchical, daisy-chained, broadcast, or other networking
protocol. These interfaces may be multi-pair as in Ethernet, or
single-wire networking protocol such as I2C. The networking
protocol may interface one or more of a variety of variants of
Ethernet and other protocols for real-time communication in an
industrial network, including Modbus.RTM. over TCP, Industrial
Ethernet, Ethernet Powerlink, Ethernet/IP, EtherCAT, Sercos.RTM.,
Profinet.TM., CAN bus, serial protocols, near-field protocols, as
well as home automation protocols such as ZigBee.RTM., Z-Wave.TM.,
or wireless WWAN or WLAN protocols such as LTE.TM., Wi-Fi,
Bluetooth.TM., or others. The sensor inputs can be permanently or
removably connected to the thing they are measuring, or may be
integrated in a standalone data acquisition box. The entire system
may be integrated into the apparatus that is being measured, such
as a vehicle (e.g., a car, a truck, a commercial vehicle, a
tractor, a construction vehicle or other type of vehicle), a
component or item of equipment (e.g., a compressor, agitator,
motor, fan, turbine, generator, conveyor, lift, robotic assembly,
or any other item as described throughout this disclosure), an
infrastructure element (such as a foundation, a housing, a wall, a
floor, a ceiling, a roof, a doorway, a ramp, a stairway, or the
like) or other feature or aspect of an industrial environment. The
entire system may be integrated into a stationary industrial system
such as a production assembly, static components of an assembly
line subject to wear and stress (such as rail guides), or motive
elements such as robotics, linear actuators, gearboxes, and
vibrators.
[1259] FIG. 156 shows an airborne drone 11730 data acquisition box
with onboard sensors 11732 and four motors 11734 to provide lift
and movement control. In embodiments, the drone 11730 has a
charging dock capability and in embodiments, a battery changing
capability so that the same drone 11730 can return to inspection
after a brief return to base for battery replacement. The drone
11730 can travel from a location near the systems to be sensed. The
drone 11730 can detect the presence of other sensor drone and avoid
collisions based on both active sensors and network-coordinated
flight plans. These sensor drones 11730 inspect and sense
environmental and apparatus conditions based on scheduled tours of
sensor reconnaissance. They also respond to specific events, either
command driven (human requests for additional data), requests from
other drone s, events such as a detected anomaly in an item to be
sensed with more scrutiny e.g., sensing by multiple drone s with
multiple sensors. They respond to AI both integrated into the drone
11730 or located in a remote server, that analyzes conditions and
generates a request for additional data and inspection of an
environment or apparatus. The drone 11730 can be configured with
multiple sensors. For instance, most drones 11730 are equipped with
some sort of visual sensor, either in visual light or infrared
range, as well as certain forms of active guidance sensor
technology such as light-pulse distance sensing, sonar-pulse
sensing. In addition, drones 11730 can be equipped with additional
sensors such as specific chemical sensors and magnetic sensors
designed to analyze the materials of specific apparatus and
machinery.
[1260] FIG. 157 shows an autonomous drone 11780 with multiple modes
of mobility, optionally including flight, rolling and walking modes
of mobility. In embodiments, telescoping and articulating robotic
legs allow positioning on uneven surfaces. In embodiments, the
drone may have four wheels. The various mobile platforms may
include articulating legs can pull up and away to allow rolling on
wheels on smooth surfaces. The legs may include end members (e.g.,
"feet") that may be enabled with various forms of attachment by
which the drone may attach to an element of its environment, such
as a landing spot on a piece of industrial equipment proximal to a
point of sensing (e.g., near a set of bearings of a rotating
component). The end members may be enabled with various forms of
attachment, such as magnetic attachment, suction cups, adhesives,
or the like. In embodiments, the drone may have multiple forms that
can be engaged by alternative mechanisms on end members (e.g.,
rotating between elements with different attachment types) or that
can be retrieved by the articulating legs from a storage location
on the drone. In embodiments, the drone 11780 may have a robotic
arm 11782 that has the ability to place an adhesive-backed hook and
loop fastener element onto a machine to allow attachment,
disengagement and reattachment by the drone at a desired landing
point. Placement may be undertaken under control of a vision
system, which may include a remote-control vision or other sensing
system and/or an automated landing system that recognizes a type of
landing point and automatically, optionally with pattern
recognition and machine learning, can land the drone and initiate
attachment. Placement may be based both on the recognition
(including by machine vision or sensor-based recognition) of an
appropriate sensing location (such as based on an identified need
for sensing, a trigger or input, or the like) and of an appropriate
landing position (such as where the drone can establish a stable
attachment and reach the point of sensing, such as with an
articulating robotic arm). In embodiments, a camera system and
other sensors can detect surface geometry and characteristics to
select appropriate landing and engagement modes (e.g., a rough
vertical surface, if recognized, can trigger use of legs and
articulated fingers to hold on, while a smooth vertical surface, if
recognized, can trigger use of suction cups or magnets to establish
temporary attachment).
[1261] In embodiments, machine learning can vary and select landing
and engagement modes by variation and selection, including testing
security of various forms of attachment. Machine learning can be,
or be initiated using, a set of rules for landing and engagement, a
set of models (which may be populated with information about
machines, infrastructure elements and other features of an
industrial environment), a training set (including one created by
having human operators land a set of drones and engage with
sensors), or by deep learning approach fusing various vision and
other sensors through a large set of trial landing and engagement
events.
[1262] In embodiments, a camera 11788 may have object recognition
capabilities (including pattern recognition improved by machine
learning, rule-based pattern matching to library of images of
machines and other features, or a hybrid or combination of
techniques).
[1263] In embodiments, sensor-based recognition of industrial
machines may be provided, where a machine is recognized based on
sensor signatures (e.g., based on matching to known vibration
patterns, heat signatures, sounds, and the like that characterize
generators, turbomachines, compressors, pumps, motors, etc.). This
may occur based on rules, models, or the like, with machine
learning (including deep learning or learning based on
human-generated training sets), or various combinations of
these.
[1264] In embodiments, the mobile platforms may contain one or more
multi-sensor data collectors (MDC) 11790 may be disposed on one or
more articulating robotic arms 11782, which may move from the
interior to the exterior of the drone 11730. In embodiments, the
drone may have one or more of its own articulating robotic arm(s)
11782, such as for picking up and placing individual sensors,
attaching sensors to a point of sensing, attaching sensors to power
sources, reading sensors, or the like.
[1265] In embodiments, the MDC 11790 can swap in and out various
sensors, both at the point of sensing and by interacting with a
central station 11792, where the drone 11730 can replenish the MDC
11790 with new or different sensors, can re-stock any disposable or
consumable elements (such as test strips, biological sensors, or
the like) or the like. Replenishment and re-stocking can be
undertaken with control elements described throughout this
disclosure that involve selection of sensor sets, including
rule-based, model-based, and machine learning control within an
expert system.
[1266] In embodiments, a drone 11730 can be paired with the central
station 11792, such as for wireless re-charging, re-stocking of
sensors, secure file downloads (e.g., requiring physical connection
and verification), or the like. The central station 11792 may have
network communication with a remote operator (including an expert
system) and/or with local operators, such as via one or more
applications, such as mobile applications, for controlling elements
of the drone 11730 or central station 11792 or for reporting or
otherwise using information collected by the drone 11730 or the
central station 11792.
[1267] In embodiments, the central station 11730 can have a 3D
printer, such as for printing suitable connectors for interfacing
with machines, for printing disposable or consumable elements used
in sensors, for printing elements such as end members for assisting
with landing, and the like.
[1268] In embodiments, the MDC 11790 has interface ports for
various forms of interface, including physical interfaces (e.g.,
USB ports, firewire ports, lighting ports, and the like) and
wireless interfaces (e.g., Bluetooth, Bluetooth Low Energy, NFC,
WiFi and the like).
[1269] In embodiments, MDC 11790 interfaces can include electrical
probes, such as for detecting voltages and currents, such as for
detecting and processing operating signatures of electrical
components of an industrial machine.
[1270] In embodiments, the MDC 11790 carries or accesses (such as
within the drone 11730, or the central station 11792) various
connectors to allow it to interface with a wide variety of machines
and equipment.
[1271] In embodiments, the camera 11788 can identify a suitable
interface port for an industrial machine and select and under user
remote control or automatically (optionally under control of an
expert system disposed on the drone 11730 or located remotely) use
the appropriate connector for the interface port, such as to
establish data communication (e.g., with an onboard diagnostic or
other instrumentation system), to establish a power connection, or
the like.
[1272] In embodiments, the robotic arm 11782 of the MDC 11790 can
insert one or more cables or connectors as needed, such as ones
retrieved from storage of the drone 11730 or from a central
station. The central station can print a new connector interface as
needed.
[1273] In embodiments, the drone 11730 is self-organizing and can
be part of a self-organizing swarm that includes intelligent
collective routing of several drones 11730 for data collection. The
drone 11730 can have and interact with a secure physical interface
for data collection, such as one that requires local presence in
order to get access to control features.
[1274] The drone 11730 may use wireless communication, including by
a cognitive, ad hoc mobile network of a mesh network of drones
11730, which mesh network may also include other devices, such as a
master controller (e.g., a mobile device with human interface).
[1275] In embodiments, the drone 11730 has a touch screen display
for user interaction and mobile application interaction.
[1276] In embodiments, the drone 11730 can use the MDC 11790 to
collect data that is relevant to placement of sensors for
instrumentation of machines (e.g., collect vibration data from a
set of possible locations and select a preferred location for data
collection, then dispose a semi-permanent vibration sensor there
for future data gathering).
[1277] Intelligent routing can include machine-based mapping,
including referencing a pre-existing map or blueprint of an
industrial environment and using machine learning to update the map
based on detected conditions (e.g., detecting by camera, IR, sonar,
LIDAR, etc., the presence of features, machines, obstacles, or the
like, whether fixed or transient and updating the map and any
relevant routes to reflect changing features).
[1278] In embodiments, the drone 11730 may include a facility for
sensor-based detection of biological signatures (e.g., IR-sensing
for base-level recognition of presence of humans, such as for
safety), as well as other physiological sensors, such as for
identity (e.g., using biometric authentication of a human before
permitting access to collected data or control functions) and human
status conditions (such as determining health status, alertness or
other conditions of humans in the environment). In embodiments, the
drone 11730 may store or handle emergency first aid items, such as
for delivery to a point of emergency in case that an emergency
health status is determined.
[1279] In embodiments, the drone 11730 can have collision detection
and avoidance (LIDAR; IR, etc.), such as to avoid collisions with
other drones 11730, equipment, infrastructure, or human
workers.
[1280] In another embodiment, the system in FIG. 157 is informed,
based on a scheduled event, to evaluate the condition of various
aspects of a factory floor. The system, configured with a learning
algorithm, takes samples of various sensors in various positions.
It is provided with positive reinforcement of a correctly operating
factory floor on a regular basis. When there is a fault it will be
instructed to evaluate the condition of various aspects and taught
that there is a fault. It records the sensor data such as
temperature, speed of motion, position sensors. It also integrates
additional sensor data such as data from sensors that are
integrated into the system to be analyzed, such as position,
temperature, and structural integrity sensors integrated in a rail
guide in an assembly line. These sensors communicate sensor data
including real-time and historical sensor data to the system via a
one of the network communication interfaces.
[1281] In another embodiment, the system in FIG. 157 has a robotic
arm and carries with it numerous attachable modules each of which
provides sensing of a different type of signal or data. For
instance, the system may carry with it four modules, capable of
sensing temperature, magnetic waves, lubricant contamination, and
rust. It is capable of attaching and detaching and securely storing
each type of module. The mobile drone 11730 is capable of returning
to a charging station and selecting additional modules to measure
additional types of signal. For instance, the system may receive an
indication that a portion of a factory has a fault in the area
where a vibrator is designed to shake tiny components into hopper
which pours into a conveyer belt, which feeds into a pick-and-place
robotic arm comprising gear boxes and actuators. The system, having
received an indication that there is a failure mode such as a
slowdown or jam in this general area, retrieves a chemical analysis
module and tests the viscosity and chemical condition of the
lubricant in the mechanical vibrator. It then retrieves a different
chemical analysis module to analyze a different type of lubricant
used in the gear box and actuator of the robotic arm. It then,
delivering the data over a network interface and receiving an
indication to continue testing, retrieves a new module capable of
detecting mechanical faults as well as a visual camera module.
Having retrieved these modules, the system then performs a visual
analysis of the parts of the assembly line and sends them to a
remote server (or keeps them locally) to be compared with
historical pictures of the same portion of assembly line. The
system continues in this way until all of the sensors which an
external system has specified (such as a manually controlling human
or a predetermined list) have been completed, or until one of the
sensors detects an anomaly which is quantified and communicated to
an external system to propose a repair.
[1282] FIG. 158 shows a drone data acquisition system which is
movably attached to a track and which can, through translational
motion and repositioning of a sensor arm, position itself in
proximity to a portion of a system to be sensed and diagnosed for
failure modes. The robotic arm 11782 is capable of positioning, for
instance, a highly sensitive metallurgical fault detection system
such as an x-ray or gamma-ray radiograph or a non-destructive
scanning electron microscope. The robotic arm 11782 positions its
sensing arm and measurement device in various positions on a static
or dynamically moving target such as a set of rolling bearings in
an assembly line. The robotic arm 11782 of the system performs
high-resolution image capture and failure mode detection on the
structural aspects of the roller bearings such as detecting if
there are any roller bearing failure modes such as pitting,
bruising, grooving, etching, corrosion, etc. The system then
communicates the findings of the failure mode detection to a remote
system over a network interface.
[1283] In another embodiment, the data acquisition system of FIG.
158 continually performs a predetermined set of measurements over
time and compares these measurements over time. For instance, it
can measure the decibels of sound received at a precisely
positioned directional sound input sensor aimed at each of a set of
roller bearings over time. When, after some time a roller bearing
diverges from the usual or common or specified decibel range for
audio, the failure mode of that specific roller bearing is
indicated, and the system then communicates the findings of the
failure mode detection to a remote system over a network
interface.
[1284] FIG. 159 shows a stationary guide rail 11800 in an
industrial environment, and below it, a pair of ports 11802
including a network interface jack and a power port jack. A mobile
data acquisition system such as a flying drone 11730 or wheeled
sensor robot approaches the guide rail and uses a moving extension
to "jack in" to the ports. At this point, the system can continue
to operate indefinitely because it is in network communication and
has continuous power. In embodiments, a remote operating user can
now activate any of the sensors available to the mobile system and
direct them to any reachable portion of the target, including the
rail guide and any machinery moving on the guide. The rail guide
can be chemically inspected, visually inspected, the portion of the
assembly line in which the rail guide operates can be visually
monitored by the remote user operating through the system sensor,
the system can perform auditory testing of the machinery operating
and moving along the rail guide. Any sensors embedded in the rail
guide can communicate their sensor data to the attached roving
system. Similarly, the sensor input from the attached roving system
can be integrated with any embedded sensor data from the rail guide
and delivered together with it over the wired network interface.
Any drone 11730 connected to hover in proximity to the rail guide
and its associated functionality can operate indefinitely and
provide "zoomed in" monitoring of that portion of the assembly
line. If a portion of an assembly line indicated a fault, a group
of drones and wheeled data acquisition systems can be recruited to
more closely monitor that area. In the case of a remote human
operator, this additional sensor visibility affords them numerous
real-time streams of sensor information on various aspects of the
portion of the assembly line. The remote human operator can
reposition and change the sensing modes of the various data
acquisition systems. In another embodiment, a remote machine
learning system operates the multiple sensing systems to zoom in
and acquire additional data about the area of the assembly line
that has been detected to be at fault. Through iterative trials and
feedback, the machine learning system operates the data acquisition
systems to test different signals with different sensors in
different positions until one or more failure modes have been
positively diagnosed. The machine learning system then takes
appropriate action such as disabling that section of the assembly
line to prevent loss of value from further damage, communicating to
an on-site operator what the diagnosed fault was, automatically
ordering the correct parts for delivery and creating a trouble
ticket in a repair system, automatically calling a service
technician to go to the location and repair the fault, estimating
the total predicted downtime and automatically updating an
accounting system with the modified throughput based on when the
system will be producing again.
[1285] FIG. 160 shows a portion of the drive train 11810 and
chassis of a vehicle 11812 such as a car or truck for
transportation or an industrial vehicle such as a tractor for use
in construction or farming. It consists of an engine 11814 a
transmission 11818, a propeller shaft 11820, a rear differential
gear box 11822, axles, and wheel ends. The various sensor drones
disclosed herein can sense, monitor, analyze and re-monitor the
vehicle 11812. The sensor drone 11730 may be airborne during its
data recording. The sensor drone 11840 may be connected to the
vehicle during the entire assembly process or at certain stations
in the process. FIG. 163 shows a portion of a turbine 11900. The
various sensor drones disclosed herein can sense, monitor, analyze
and re-monitor the turbine 11900. The sensor drone 11730 may be
airborne during its data recording. The sensor drone 11840 may be
connected to the vehicle during the entire assembly process or at
certain stations in the process. These various components are
metallic and are subject to wear and damage from overuse and
underuse outside their duty cycle and working output range. In
order to operate this equipment and maintain these various
components in proper order, numerous sensors are disposed
throughout these. Conventionally, the most active elements such as
the transmission contain numerous sensors which are used to operate
the device correctly and provide feedback, but not necessarily to
diagnose or monitor the health or failure modes of the device.
These sensors include throttle position sensors, mass air flow
sensors, brake sensors various pressure and temperature, and fluid
level sensors. These same sensors along with numerous other
additional sensors can be used not only for operation but for
maintenance and diagnosis of the device. Additional sensors which
can be permanently installed and distributed throughout include
lubricant pollution chemical sensors such as solid-state sensors,
gear position sensors, pressure sensors, fluid leak sensors,
rotational sensors, bearing sensors, wheel tread sensors, visual
sensors, audio sensors, and numerous other sensors listed
herein.
[1286] FIG. 161 shows a micro, mobile magnetically driven
attachable drone sensor system 11840 that attaches to metal and can
be used to perform analysis of a vehicle in motion or at rest. It
consists of a small rectangular or square mobile sensor unit which
can be sized smaller than a matchbox. It has numerous wheels or
castors or ball bearings and it attaches to metal using a permanent
or electromagnet. It can be curved to mate more easily to curved
surfaces such as a rear differential or drive or propeller
shaft.
[1287] FIG. 162 shows a closer view of the mobile sensor system,
showing its wheels and four sensors, an ultrasonic sensor, a
chemical sensor, a magnetic sensor and a visual (camera) sensor.
The system travels around and throughout the target area for
failure mode detection, such as the undercarriage of a
transportation or industrial vehicle. The sensor captures
comprehensive data and is capable of covering the entire surface
and undercarriage of the vehicle and can detect faults such as
rusted out components, chemical changes, fluid leaks, lubricant
leaks, foreign contamination, acids, soil and dirt, damaged seals,
and the like. The sensor system reports this information over a
network interface to another sensor, to a computer on the vehicle
itself, or to a remote system in order to facilitate data capture
and ensure that the data is fully recorded. The system also runs on
a periodic basis performing the same or similar coverage of the
vehicle so that a baseline measurement can be compared with later
measurements to determine the state of maintenance of the vehicle.
This can be used to detect failure modes but can also be used to
create an image of the vehicle for insurance, for depreciation, for
maintenance scheduling, or surveillance purposes.
[1288] In embodiments, the mobile attaching drone sensor 11840 can
be removably attached to a portion of a vehicle and can move freely
around the undercarriage of a vehicle. It can also be placed there
as a sensing module by the mobile robotic sensor system of FIG. 157
and subsequently retrieved when it has completed its sensing
tasks.
[1289] In embodiments, the mobile attaching sensor 11840 may take
the form of a swimming device that can travel through fluid, or a
multi-pedal unit with chemically-adhesive or magnetic or
vacuum-adhesive pods or feet that allow it to move freely on the
surface of a target to be sensed.
[1290] In embodiments, the modular sensors shown in FIG. 157 can be
removably or permanently integrated into mobile or portable sensors
such as drones, multi-pedal or wheeled industrial measurement
robots, or self-propelled floating, climbing, swimming, or
magnetically crawling micro-data acquisition systems Any of the
sensors can take multiple measurements from different positions on
the same target to get a fuller picture of the health or condition
of the target.
[1291] The sensors deployed on the various drones, mobile
platforms, robots, and the like may take numerous forms. For
instance, a set of roller bearing sensors may be integrated within
the roller bearing itself, using the energy off the motion of the
roller bearing to generate an inductive force sufficient to
generate data signals to communicate to a data circuit the state of
the roller bearing, such as velocity, rotations per unit time, as
well as analog data indicating any minor perturbations in the
smooth rotation of the bearing over time. A deformation sensor can
take the form of a passive (visual, infrared) or active scanning
(Lidar, sonar) system that captures data from a target and compares
it to historical data on the shape or orientation of the component
to detect variations. Camera sensors are configured with a lens to
capture continuous and still visible and invisible photon
information cast upon or reflected by a target. Ultraviolet sensors
can similarly capture continuous and still frame information about
a target and its surrounds. Infrared sensors can capture light and
heat emission data from a target. Audio sensors such as directional
and omnichannel microphones can measure the frequency and amplitude
of sonic wave data emitting from a target or its environment, and
this data can be compared over time to detect anomalies when the
amplitude or quality of the sound generated by the target exceeds
or varies from predetermined or historical levels. Vibration
sensors can be used in a similar manner, capturing extremely low
frequency sound as well as physical perturbations and rhythms of a
target over time. Viscosity sensors can be installed in-line in the
lubrication system of a system or vehicle or can be movable and
make ad-hoc measurements and evaluations of the continuous or
instantaneous viscosity of the lubricating material for a target.
Chemical sensors can vary widely in what analyte (target chemical)
they detect, and in the case of vehicles or stationary machinery,
can be configured with variable receptors capable of capturing and
recognizing numerous conditions of a target. Specific target
sensors such as rust sensors or overheat sensors can sense when a
target such as an apparatus, metal structure or chemical lubricant
has started to change chemically over time. These chemical sensors
can be multi- or single-purpose, and can be integrated within a
structure, such as the frame or chassis of a vehicle or the
stationary or movable portions of an assembly line, or the
mechanical motive power of an engine or robotic machinery. Or they
can be attached to a portable self-propelled data acquisition
system that is deployed to measure the target. When activated these
chemical sensors make contact or take samples from the target and
perform chemical analysis and report the state of the results to a
data circuit. A solid chemical sensor can take solid chemical
samples (rather than gaseous or liquid samples) and determine the
presence of a particular chemical or the composition by detecting
multiple chemicals in a sample. A pH sensor can be used to detect
the level of acidity of a target and can be used to determine
specific changes in the environment of a target, the fluid
conditions surrounding a target, or the state of an operational
fluid such as a coolant or lubricant in a target, and similarly,
fluid, and gaseous chemical sensors perform additional component
and presence detection on these targets. A lubricant sensor can be
as simple as an indicator of whether sufficient lubricant is still
present (by detecting chafing or a lack of distance between
conductive or hard components) or can use a combination of
chemical, pressure, visual, olfactory, or vibrational feedback
tests (vibrating the target and measuring response) to determine
the instant or continuous presence or quantity of lubricant in a
target. Contaminant sensors can look for the presence of foreign or
damaged elements added to the surface, substance or fluid contents
of a target, such as a lubricant which has been contaminated with
metal particles from component wear, or when a lubricant or motive
fluid such as in a pneumatic has been contaminated due to the
breaking of a seal. Particulate sensors can detect the presence of
specific types of particles within a fluid or on a target. Weight
or mass sensors can determine the continuous or changing weight of
a component, and can be on coarse scale such as a weighing device
for weighing large machinery down to an integrated MEMS scale that
determines the continuous and instantaneous changes in weight of a
target that may lose mass over time due to damage or abrasion or
evaporation, sublimation, etc. A rotation sensor can be optical,
audio-based, or use numerous other techniques to detect the
periodic acceleration, velocity, and frequency of rotation of a
target. Temperature sensors can be configured to measure coarse
environmental temperature in a general area as well as fine
environmental temperatures, precise temperature of a region of a
target component and can be disposed throughout an engine, a
robotic system, or any stationary or moving component. Temperature
sensors can also be mobile and deployed to take periodic or ad-hoc
measurements of a target component, surface, material, or system to
determine if it is operating in a correct temperature range.
Position sensors can be as simple as interrupted visual
reflections, to visual systems with image-recognition algorithms
being performed on continuous video, to magnetic or mechanical
switch systems that durably detect either precisely or coarsely the
position of various moveable elements with respect to one another.
Ultrasonic sensors can be used for a variety of distance, shape,
solidity, and orientation measurements by projecting ultrasonic
energy in the direction of a target or group of targets or
measuring the reflected ultrasonic energy reflected by those
targets. Ultrasonic sensors may comprise multiple emitters and
receivers in order to add dimensions and precision to the
measurements and even produce 2D or 3D outlines of a region for
further analysis. A radiation sensor can detect the presence of
forms of radioactivity as alpha, beta, gamma, or x-ray radiation
and some can identify the directional source, the field and area of
the radiation and the intensity. An x-ray radiograph can actively
determine structure, structural changes and structural defects as
well as providing a visual depiction of otherwise obscured physical
characteristics of a target. Similarly, a gamma-ray radiograph can
be used to penetrate solid targets such as steel or other metallic
objects and so determine the characteristics of physical features
such as joints, welds, depths, rough edges, and thicknesses in load
bearing and pressurized targets. Various forms of high-resolution
scanning technologies exist including scanning tunneling
microscopes, photon tunneling microscope, scanning probe
microscopes, and these measurement devices have been miniaturized
and non-destructive forms of these devices can be brought in
contact with a target to be measured, such as via a movable robot
or drone 11730, and then used to perform extremely high resolution
(atomic-scale) measurements and analysis of the structure and
characteristics of a target. A displacement meter can be
implemented using capacitive effects, mechanical measurement or
laser measurement and can be used similarly to a position meter to
measure the location of a movable target and can be used, for
instance, to measure the `play` or changing displacement of a
wearing physical target over time. A magnetic particle inspector
can be used to determine if a fluid such as a lubricant, an
immersive fluid container, a coolant, or a pneumatic fluid, for
instance, contain trace elements of ferromagnetic particles, which
could be an indication of the decay or failure of a metal
component. An ultraviolet particle detector can be used to detect
contamination such as in gaseous targets. A load sensor such as a
static load sensor (measuring systems at rest) or an axial load
sensor that detects, such as magnetically, the pushing and pulling
forces along a beam and can be used to determine the forces on an
axle or other torque-transmitting tube or shaft. An accelerometer
can be microscopic in size, implemented as a MEMS device, or
packaged as a larger industrial device and can provide multiple
dimensions of acceleration and gravitation data about or in
proximity to a target, and can be useful for instance to detect if
a device is level, or in addition to other data collection, the
amount of force being applied to a target over time. A speed sensor
can be used to measure translational, displacement or rotational
velocity or speed. A rotational sensor can be used to measure the
speed, period, frequency, even or uneven motion of a rotating
element such as a tire, a gear, an armature, or a gyro. A moisture
sensing device can detect the liquid, condensation or H.sub.2O
content of the target or its environment. A humidity sensor can
measure the degree of water vapor in the atmosphere in the vicinity
of a target. Ammeters, voltmeters, flux meters, and electric field
detectors can be used to measure electromagnetic effects, fields
and levels of a target or in the vicinity of a target, or the
electronic or magnetic emission of a target, or the potential
energy stored in a target. A gear box sensor can measure numerous
attributes of an industrial gear box for general translation of
motive power in a robotic or assembly line environment as well as
numerous complex vehicular gear assemblies including vehicle
transmissions and differentials. Measurements can include the
precise position of all internal gears, the state of wear of gear
elements and teeth, various chemical, temperature, pressure,
contamination, coolant level, fluid level, vacuum level, seal
level, torsion, torque, force, shear stress, cycle count, tooth
gap, wear, and any other changing physical attribute. A gear wear
sensor and "tooth decay" sensor can specifically measure and convey
the degree to which gears have worn down or that the teeth of the
gears have been chipped, cracked, flaked off or otherwise reduced
from original condition, and this can be accomplished through
visual or other emitting signal sensors, audio sensors (measuring
change in sonic quality based on the change in impact of teeth),
laser sensors (measuring the periodic interruption of a precise
beam across each gear path), power transmission measurement
(measuring loss of power from one gear to the next via torque or
force measurement) and numerous other techniques. A transmission
input speed sensor measures the rotational velocity of the shaft
entering the transmission and can do this with rotational position
sensors plotted against time. Transmission output speed sensors
measure the rotational velocity of the shaft delivering motive
force out of the transmission. A manifold airflow sensor or mass
air flow sensor can be used to measure the air density or intake
airflow of an engine and thus determine the amount of engine load,
torque, or power output. Other types of engine load sensors can be
used to determine how much power or torque is being delivered from
an engine, such as by measuring the delivered axle speed vs. the
expected axle speed or by measuring the work being produced. A
throttle position sensor measures the position of an engine
throttle regulating the amount of fuel and air entering an engine,
and can be measured using various techniques such as hall effect
sensing, inductive, mechanical position sensing, magneto resistive
sensing, and other techniques. A coolant temperature sensor
measures the coolant temperature in various positions, over time or
instantaneously in a liquid or gas cooled target system. A speed
sensor can measure rotational or linear speed or speed of an
overall vehicle over a path or a moving part in rotational or
translational motion. A brake sensor can measure various aspects of
a vehicular or robotic braking system the degree to which a brake
activation switch (such as a vehicular brake pedal) is depressed,
or the degree to which a brake is activated or the degree to which
a brake is making frictional or other speed-suppressing contact
with the motion system. A fluid temperature sensor can measure the
temperature of any fluid such as a gaseous, pressurized, lubricant,
cooling, fuel, or transported substance and can measure it in a
single location or in various locations throughout the body of the
fluid, and such measurements can be achieved through integrated
contact sensors, dispersed contact sensors around the perimeter of
a container, or through active or passive measurement such as
infrared sensing or measuring the effect of applied energy to a
portion of a fluid and the reflected or measured effect, such as
with a laser thermometer. An emitting thermometer tool can be
directed to various portions of a three-dimensional fluid chamber
to be measured. A tool load sensor can be used to determine the
amount of power being delivered from a tool and the resistance of
the moving parts against the expected unloaded power of that
device. A bearing sensor can measure the forces in portions or
throughout or at periodic intervals in a bearing and thus allow a
system to measure the change in these forces over time, as well as
measure other aspects of a mechanical bearing such as position,
service life, rotational count, change in average velocity, sonic
changes, vibrational changes, chemical changes, color changes,
surface changes, contamination changes, and numerous other
attributes relevant to change of the bearing and its potential
performance over time. A standstill counter can measure when and
how often and for how long and how rapidly a movable target is
stationary and in what internal position (as in a rotational or
movable element) or relative position (as in a device that
interfaces with another device) the moveable target is holding
still, which can amongst other things indicate a location where a
device, by sitting in that specific position may develop a fault or
unwanted physical asymmetry. A hydraulic pump or power unit sensor
can sense the pressure within the hydraulic fluid that provides
power and also help detect, based on non-linearity or other
specific signals that the hydraulic fluid is aged, compromised,
contaminated, oxygenated or otherwise at fault. Hydraulic pump and
power unit sensors can also sense other aspects of a pump or power
unit including service duration, displacement, current position,
divergence from duty cycle, change in range of motion or velocity
curve of motion over time, resistance, fluid temperatures and
chemical state of the fluid enclosure, enclosure integrity, and
other intrinsic aspects of the pump. An oxygen sensor can sense the
presence, quantity, or density of oxygen in the environment or in a
target container. Gas sensors can detect specific types of gas
compositions using either a consumable chemical reagent or a
solid-state chemical sensor and can detect the presence, quantity
or density of a particular gas or combination of gasses in an
environment or target container. Oil sensors can detect the
presence of oil, its viscosity, its level of pollution, and its
pressure in a target area or container. A chemical analysis sensor
can use consumable or permanent sensors to analyze a sample and
determine the presence of a single chemical molecule or element or
the composition of a sample and the specific multiple chemicals
that make it up and their relative quantities. Chemical analysis
sensors use various techniques including spectral analysis,
exposure to lights, combination with consumable test strips,
solid-state chemical sensors, and other techniques to establish the
chemical makeup of a target. Pressure detectors can detect the
pressure in an environment (such as barometric pressure) or can be
movably linked to an openable shaft such as with an inflatable
object or tire with a tire stem or a pneumatic device or a
gas-filled device such as a refrigerant unit, and can measure the
pressure therein. Pressure detectors can also be permanently
installed within a compressed or vacuum chamber and communicate
their measurements through a wired or wireless channel. A vacuum
detector can measure the level the relative state of pressure of
the interior and can also produce a result simply indicative of
whether a predetermined level of vacuum exists in a chamber. A
densitometer can measure the optical density e.g., degree of
darkness of a sample, by projecting one or more forms of light on
it and measuring absorption. A torque sensor can measure the
dynamic or static torque of a rotating element using techniques
such as magneto elastic sensing, strain gauges, or surface acoustic
waves. Engine sensors can measure numerous aspects of an engine,
including pressures, temperatures, relative positions, velocities,
accelerations, fluid dynamics, power transfer, and numerous other
states in a vehicle or other power-generating engine. Exhaust and
exhaust gas sensors can measure the output of an exhaust system for
attributes such as relative chemical composition, presence of
specific chemicals, pressure, velocity, quantity of specific
particles, particle count, and quantity of specific pollutants.
Exhaust sensors can be disposed within the one or more pipes or
channels through which exhaust exits, and can be composed of
numerous different sensors including catalytic sensors, optical
sensors, mechanical and chemical sensors that analyze the exhaust.
A crankshaft sensor or crankshaft position sensor
can use optical, magnetic, electrical, electromechanical, or other
techniques to establish and report the real-time velocity of a
crankshaft or its position relative to other components including
the specific position of the pistons in a reciprocating motor. A
camshaft position sensor can use optical, magnetic, electrical,
electromechanical, or other techniques to establish the position of
the camshaft and can feed this back to ignition and fuel delivery
systems in a feedback loop as well as provide the information to an
external system for analysis. A capacitive pressure sensor uses
capacitive electrical effects to measure the pressure inside a
target chamber. A piezo-resistive sensor can be used to measure
strain and distortion of surfaces and devices under load. A
wireless sensor can encompass a wide range of different sensing
units that deliver the information they sense over a wireless
connection. A wireless pressure sensor performs pressure sensing
and delivers the results over a wireless connection. A fuel sensor
can use pressure, optical sensing, mechanical sensing with a float,
weight, or displacement sensing to determine the level of fuel
within a tank, and other types of fuel sensors can sense fuel flow
as it passes through a channel or into a chamber. A gyro sensor can
measure angular or rotational velocity and can produce signals
useful for physical stabilization and motion sensing. Mechanical
position sensors measure physical displacement, angular
displacement, relative position or orientation using mechanical,
optical, magnetic, electrical, or other sensing techniques. MEMS
(Micro-electrical-mechanical) are microfabricated sensors which can
be integrated into objects to be measured or integrated in mobile
sensing devices and MEMS sensors encompass various sensing devices
including pressure sensors, magnetic field sensing, accelerometers,
fluid quantity sensors, microscanning sensors, micromirror steering
devices for sensing, ultrasound transducing, as well as MEMS
devices that harvest energy which can be used to power the
transmission of sensor data. An injector sensor may sense
characteristics of a fuel delivery such as the quantity, speed, or
timing of fuel injection. An NOx sensor detects the pollutant
nitrogen oxide such as in exhaust systems. A variable valve timing
sensor can be used in feedback systems to verify and help control
the timing of valve lifting in an engine equipped with variable
valve control for fuel efficiency and performance optimization A
tank pressure sensor can detect evaporative leaks in a gasoline or
diesel fuel tank due to an absent gas cap, and in other tank
applications such as pressurized tanks can detect how full a
gaseous tank is. A fuel flow sensor is a specialized fluid flow
sensor, both of which can measure the quantity of a gas or liquid
passing through a region in a unit time, such as water or fuel or
gasses in a pipe or flue. An oil pressure sensor can be located in
various places in an engine, transmission, gearbox, or other sealed
lubricating system to help determine the performance and
sufficiency of the lubricant. A damper sensor or throttle position
sensor measures the position of a partial valve system and can
measure the degree of flow permitted in an intake, exhaust and
other flow damper or throttle engine or industrial system. A
particulate sensor or particulate matter sensor can detect specific
air quality conditions such as the presence of particulates and
dust. An air temperature sensor can be located in various portions
of an engine to receive data that can help optimize the air/fuel
mixture in an engine. A coolant temperature sensor can sense the
temperature of coolant passing through an area or stored in a
chamber and help determine if a cooling system is operating as
intended. An in-cylinder pressure sensor can capture data about the
instantaneous pressure in a motor cylinder and so optimize the
combustion in an engine. An engine speed sensor can sense the
rotational motion of the crankshaft using optical or
magneto-electric sensing. A knock sensor uses vibration sensing to
measure the magnitude and timing of detonation in an engine and can
be used to adjust the ignition timing. A drive shaft sensor can
measure numerous aspects of a power-delivering shaft including
angular velocity, power transfer, and may incorporate specific
sensors for various modes of vibration such as a torsional
vibration sensor, a transverse vibration sensor, a critical speed
vibration sensor which detects vibration at the natural frequency
of the object leading to failure modes, and a component failure
vibration sensor which can detect failure modes in u-joints or
bolts. An angular sensor can measure the angular position of a
mechanical body with respect to a reference point. A powertrain
sensor encompasses various sensors throughout the
engine-transmission-driveshaft-differential-wheel system. An engine
sensor can include a power sensor encompassing various sensors that
detect the level of power being delivered by the engine. Engine oil
sensors can sense oil pressure, temperature, viscosity, and flow. A
load sensor can sense weight or strain in a static configuration. A
frequency sensor can measure various frequencies or provide
positive confirmation that a signal or input is maintaining a
particular frequency. A transfer case sensor in four-wheel or
all-wheel drive vehicles can detect the position of the gears (high
or low). A differential sensor such as a rear wheel speed sensor
indicates the axle speeds of the rear wheels, such as for an
antilock braking system. Various other sensors in the rear
differential can detect conditions such as lubricant sufficiency,
seal, power transfer, slip, etc., A tire pressure gauge is a
specialized form of pressure gauge and can be integrated with a hub
or rim in the valve stem or can be non-integrated and connected to
the valve stem as needed. A tire damage gauge can sense pressure
loss, traction loss, or using other sensor techniques determine
various attributes of a tire such as wear, tear, balding,
splitting, puncture, and the like. A tire vibration or balance
sensor can sense when a wheel is not smoothly rotating. Hub and rim
integrity sensors can measure and detect the structural integrity
and stability of wheels through chemical, electromagnetic, optical,
or visual sensing. Air, fluid and lubricant leak sensors can detect
the loss of air or fluid through various means including pressure
change over time, visual detection of a puncture, emission of gas
or liquid from the exterior of the containing vessel, or
temperature gradient detection such as with infrared sensing.
Lubricant leak sensors can also detect a loss of lubricant through
increased noise due to abrasion, fine measures of distances and
contacts between parts, vibrations, and off-balance motions in a
system.
[1292] The sensors described herein can deliver their instantaneous
or continuous sensor data via numerous data transmission
techniques, including techniques such as low-distance wireless
transmission where the power to emit the transmission is provided
by an inductive or mechanical generator which is powered by the
motion or energy being sensed. The sensor data can be delivered via
a single wire or even body-current transmission protocol over any
practical energy emission device. For instance, a pressure sensor
embedded within a ferrometallic block could use the fluctuations in
temperature to induce a tiny magnetic flux in the block, which flux
is then measured in another area of the block by a sensor
communicating via a conventional Wi-Fi or Ethernet network. MEMS
devices integrated in the sensing components can perform energy
harvesting in order to power the transmission of the sensor data
over a network.
[1293] In embodiments, a system for data collection in an
industrial environment having a self-sufficient data acquisition
box for capturing and analyzing data in an industrial environment
comprises a data circuit for analyzing a plurality of sensor
inputs, a network communication interface, a network control
circuit for sending and receiving information related to the sensor
inputs to an external system and a data filter circuit configured
to dynamically adjust what portion of the information is sent based
on instructions received over the network communication interface.
In embodiments, the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a roller bearing
assembly such as rust, micropitting, macropitting, gear teeth
breakage, fretting, case-core separation, plastic deformation,
scuffing, polishing, adhesion, abrasion, subcase fatigue, erosion,
corrosion, electric discharge, cavitation, cracking, scoring,
profile pitting, and spalling.
[1294] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in a gear box
such as micropitting, macropitting, gear tooth wear, tooth
breakage, spalling, fretting, case-core separation, plastic
deformation, scuffing, polishing, adhesion, abrasion, subcase
fatigue, erosion, electric discharge, cavitation, rust, corrosion,
and cracking.
[1295] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in a hydraulic
pump such as fluid aeration, overheating, over-pressurization,
lubricating film loss, depressurization, shaft failure, vacuum seal
failure, large particle contamination, small particle
contamination, rust, corrosion, cavitation, shaft galling, seizure,
bushing wear, channel seal loss, and implosion.
[1296] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in an engine such
as imbalance, gasket failure, camshaft, spring breakage, valve
breakage, valve scuffing, valve leakage, clutch slipping, gear
interference, belt slipping, belt teeth breakage, belt breakage,
gear tooth failure, oil seal failure, aftercooler, intercooler, or
radiator failure, rod failure, sensor failure, crankshaft failure,
bearing seizure, overload at low RPM, cranking, full stop, high
RPM, overspeed, piston disintegration, shock overload, torque
overload, surface fatigue, critical speed failure, weld failure,
and material failures including micropitting, macropitting, gear
teeth breakage, fretting, case-core separation, plastic
deformation, scuffing, polishing, adhesion, abrasion, subcase
fatigue, rust, erosion, corrosion, electric discharge, cavitation,
cracking, scoring, profile pitting and spalling.
[1297] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in a vehicle
chassis, body or frame such as imbalance, gasket failure, spring
breakage, lubricant seal failure, sensor failure, bearing seizure,
shock overload, surface fatigue, weld failure, spring failure,
strut failure, control arm failure, kingpin failure, tie-rod and
end failure, pinion bearing failure, pinion gear failure, and
material failures including micropitting, macropitting, fretting,
rust, erosion, corrosion, electric discharge, cavitation, cracking,
scoring, profile pitting and spalling.
[1298] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in a powertrain,
propeller shaft, drive shaft, final drive, or wheel end, such as
imbalance, gasket failure, camshaft failure, gear box failure,
spring breakage, valve breakage, valve scuffing, belt teeth
breakage, belt breakage, gear tooth failure, oil seal failure, rod
failure, sensor failure, crankshaft failure, bearing seizure,
overload at low RPM, cranking, full stop, high RPM, overspeed,
piston disintegration, shock overload, torque overload, surface
fatigue, critical speed failure, yoke damage, weld failure, u-joint
failure, CV joint failure, differential failure, axle shaft
failure, spring failure, strut failure, control arm failure,
kingpin failure, tie-rod & end failure, pinion bearing failure,
ring gear failure, pinion gear failure, spider gear failure, wheel
bearing failure, and material failures including micropitting,
macropitting, gear teeth breakage, fretting, case-core separation,
plastic deformation, scuffing, polishing, adhesion, abrasion,
subcase fatigue, rust, erosion, corrosion, electric discharge,
cavitation, cracking, scoring, profile pitting and spalling.
[1299] In embodiments, the sensor input can be a roller-bearing
sensor, deformation sensor, camera, ultraviolet sensor, infrared
sensor, audio sensor, vibration sensor, viscosity sensor, chemical
sensor, contaminant sensor, particulate sensor, weight sensor,
rotation sensor, temperature sensor, position sensor, ultrasonic
sensor, solid chemical sensor, pH sensor, fluid chemical sensor,
lubricant sensor, radiation sensor, x-ray radiograph, gamma-ray
radiograph, scanning tunneling microscope, photon-tunneling
microscope, scanning probe microscope, laser displacement meter,
magnetic particle inspector, ultraviolet particle detector, load
sensor, static load sensor, axial load sensor, accelerometer, speed
sensor, rotational sensor, moisture, humidity, ammeter, voltmeter,
flux meter, and electric field detector, gear box sensor, gear wear
sensor, "tooth decay" sensor, rotation sensors, transmission input
sensor, transmission output sensor, manifold airflow sensor
(determines engine load and thus affects gearbox), engine load
sensors, throttle position sensor, coolant temperature sensor,
speed sensor, brake sensor, fluid temperature sensor, tool load
sensor, bearing sensor, standstill counter, hydraulic pump sensor,
oxygen sensors, gas sensors, oil sensors, chemical analysis,
pressure detector, vacuum detector, densitometer, torque sensor,
engine sensor, exhaust sensors, exhaust gas sensor, crankshaft
position sensor, camshaft position sensor, capacitive pressure
sensor, piezo-resistive sensor, wireless sensor, wireless pressure
sensor, chemical sensors, oxygen sensor, fuel sensor, gyro sensor,
mechanical position sensors, accelerometer, mems sensors, digital
sensors, mass air flow sensor, manifold absolute pressure sensor,
throttle control sensor, injector sensor, NOx sensor, variable
valve timing sensor, tank pressure sensor, fuel level sensor, fuel
flow sensor, fluid flow sensor, damper sensor, torque sensor,
particulate sensor, air flow meter, air temperature sensor, coolant
temperature sensor, in-cylinder pressure sensor, engine speed
sensor, knock sensor, drive shaft sensor, angular sensor,
transverse vibration sensor, torsional vibration sensor, critical
speed vibration sensor, powertrain sensor, engine sensors: power
sensor, oil pressure, oil temperature, oil viscosity, oil flow
sensor, load sensor (structural analysis), vibration sensor,
frequency sensor, audio sensor, transfer case sensor, differential
sensor, tire pressure gauge, tire damage gauge, tire vibration
sensor, hub and rim integrity sensors, air leak sensors, fluid leak
sensors, and lubricant leak sensors.
[1300] In embodiments, the sensor inputs additionally comprise
microphones or vibration sensors configured to detect vibrational
or audio-frequency conditions in movable or rotational components,
such as whirring, howling, growling, whining, rumbling, clunking,
rattling, wheel hopping, and chattering.
[1301] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in a production
line gear box, such as micropitting, macropitting, gear tooth wear,
tooth breakage, spalling, fretting, case-core separation, plastic
deformation, scuffing, polishing, adhesion, abrasion, subcase
fatigue, erosion, electric discharge, cavitation, corrosion, and
cracking.
[1302] In embodiments, the data circuit is configured to analyze
data indicative of a fatigue or wear failure mode in a production
line vibrator such as moisture penetration, contamination,
micropitting, macropitting, gear tooth wear, tooth breakage,
spalling, fretting, case-core separation, plastic deformation,
scuffing, polishing, adhesion, abrasion, subcase fatigue, rust,
erosion, electric discharge, cavitation, corrosion, and
cracking.
[1303] In embodiments, analyzing comprises detecting anomalies in
the received data. In embodiments, the data filter circuit executes
stored procedures to create digests of the information. In
embodiments, the system discards the data underlying the digests of
the information after a user-configurable time period.
[1304] In embodiments analyzing comprises determining what data to
store, determining what data to transmit, determining what data to
summarize, determining what data to discard, or determining the
accuracy of the received data.
[1305] In embodiments, the system is configured to communicate with
a plurality of other similarly configured systems and store the
information when the amount of storage used by the system exceeds a
threshold.
[1306] In embodiments, the system is configured to execute the
instructions received via the network communication interface using
a virtual machine.
[1307] In embodiments, the system further comprises a digitally
signed code execution environment to decrypt and run the
instructions it receives via the network interface.
[1308] In embodiments, the system further comprises multiple
distinct cryptographically protected memory segments.
[1309] In embodiments, the at least one of the memory segments is
made available for public interaction with the stored data via a
public key-private key management system.
[1310] In embodiments, the system further comprises a conditioning
circuit for converting signals to a form suitable for input to an
analog-to-digital converter.
[1311] In embodiments, a system for data collection in an
industrial environment having a self-sufficient data acquisition
box for capturing and analyzing data in an industrial process,
comprises a data circuit for analyzing a plurality of sensor
inputs, a network control circuit for sending and receiving
information related to the sensor inputs to an external system, and
a storage device, where the data circuit continuously monitors
sensor inputs and stores them in an embedded data cube and where
the data acquisition box dynamically determines what information to
send based on statistical analysis of historical data.
[1312] In embodiments, the system further comprises a plurality of
network communication interfaces. In embodiments, the network
control circuit bridges another similarly configured system from
one network to another using the plurality of network communication
interfaces. In embodiments, the analyzing further comprises
detecting anomalies in the information. In embodiments, the data
circuit executes stored procedures to create digests of the
information. In embodiments, the data circuit supplies digest data
to one client and non-digest data to another client simultaneously.
In embodiments, the data circuit stores digests of historical
anomalies and discards at least a portion of the information. In
embodiments, the data circuit provides client query access to the
embedded data cube in real time. In embodiments, the data circuit
supports client requests in the form of a SQL query. In
embodiments, the data circuit supports client requests in the form
of a OLAP query. In embodiments, the system further comprises a
conditioning circuit for converting signals to a form suitable for
input to an analog-to-digital converter.
[1313] In embodiments, a system for data collection in an
industrial environment having a self-sufficient data acquisition
box for capturing and analyzing data in an industrial process
comprises a data circuit for analyzing a plurality of sensor
inputs, and a network control circuit for sending and receiving
information related to the sensor inputs to an external system, the
system is configured to provide sensor data to a plurality of other
similarly configured systems, and the system dynamically
reconfigures where it sends data and the and the quantity it sends
based on the availability of the other similarly configured
systems.
[1314] In embodiments, the system further comprises a plurality of
network communication interfaces. In embodiments, the network
control circuit bridges another similarly configured system from
one network to another using the plurality of network communication
interfaces. In embodiments, the dynamic reconfiguration is based on
requests received over the one or more network communication
interfaces. In embodiments, the dynamic reconfiguration is based on
requests made by a remote user. In embodiments, the dynamic
reconfiguration is based on an analysis of the type of data
acquired by the data acquisition box. In embodiments, the dynamic
reconfiguration is based on an operating parameter of at least one
of the system and one of the similarly configured systems. In
embodiments, the network control circuit sends sensor data in
packets designed to be stored and forwarded by the other similarly
configured systems. In embodiments, when a fault is detected in the
system, the network control circuit forwards a at least a portion
of its stored information for to another similarly configured
system. In embodiments, the network control circuit determines how
to route information through a network of similarly configured
systems connected, based on the source of the information request.
In embodiments, the network control circuit decides how to route
data in a network of similarly configured systems, based on how
frequently information is being requested. In embodiments, the
decides how to route data in a network of similarly configured
systems, based how much data is being requested over a given
period. In embodiments, the network control circuit implements a
network of similarly configured systems using an intercommunication
protocol such as multi-hop, mesh, serial, parallel, ring, real-time
and hub-and-spoke. In embodiments, after a configurable time
period, the system stores only digests of the information and
discards the underlying information. In embodiments, the system
further comprises a conditioning circuit for converting signals to
a form suitable for input to an analog-to-digital converter.
[1315] In embodiments, a system for data collection in an
industrial environment having a self-sufficient data acquisition
box for capturing and analyzing data in an industrial process,
comprises a data circuit for analyzing a plurality of sensor
inputs, a network control circuit for sending and receiving
information related to the sensor inputs to an external system,
where the system provides sensor data to one or more similarly
configured systems and where the data circuit dynamically
reconfigures the route by which it sends data based on how many
other devices are requesting the information.
[1316] In embodiments, the system further comprises a plurality of
network communication interfaces. In embodiments, the network
control circuit bridges another similarly configured system from
one network to another using the plurality of network communication
interfaces. Where the network control circuit implements a network
of similarly configured systems using an intercommunication
protocol such as multi-hop, mesh, serial, parallel, ring, real-time
and hub-and-spoke. In embodiments, the system continuously provides
a single copy of its information to another similarly configured
system and directs requesters of its information to the another
similarly configured system. In embodiments, the another similarly
configured system has different operational characteristics than
the system. In embodiments, the different operational
characteristics can be power, storage, network connectivity,
proximity, reliability, duty cycle. In embodiments, after a
configurable time period, the system stores only digests of the
information and discards the underlying information.
[1317] In embodiments, a system for data collection in an
industrial environment having a self-sufficient data acquisition
box for capturing and analyzing data in an industrial process
comprises a data circuit for analyzing a plurality of sensor
inputs, a network control circuit for sending and receiving
information related to the sensor inputs to an external system,
where the system provides sensor data to one or more similarly
configured systems and where the data circuit dynamically nominates
a similarly configured system capable of providing sensor data to
replace the system.
[1318] In embodiments, the nomination is triggered by the detection
of a system failure mode. In embodiments, when the system is unable
to supply a requested signal it nominates another similarly
configured system to supply similar but not identical information
to a requestor. In embodiments, the system indicates to the
requestor that the new signal is different than the original. In
embodiments, the network control circuit implements a network of
similarly configured systems using an intercommunication protocol
such as multi-hop, mesh, serial, parallel, ring, real-time and
hub-and-spoke. In embodiments, after a configurable time period,
the system stores only digests of the information and discards the
underlying information. In embodiments, the network control circuit
self-arranges the system into a redundant storage network with one
or more similarly configured systems. In embodiments, the network
control circuit self-arranges the system into a fault-tolerant
storage network with one or more similarly configured systems. In
embodiments, the network control circuit self-arranges the system
into a hierarchical storage network with one or more similarly
configured systems. In embodiments, the network control circuit
self-arranges the system into a hierarchical data transmission
configuration in order to reduce upstream traffic. In embodiments,
the network control circuit self-arranges the system into a
matrixed network configuration with multiple redundant data paths
in order to increase reliability of information transmission. In
embodiments, the network control circuit self-arranges the system
into a matrixed network configuration with multiple redundant data
paths in order to increase reliability of information transmission.
In embodiments, the system accumulates data received from other
similarly configured systems while an upstream network connection
is unavailable, and then sends all accumulated data once the
upstream network connection is restored. In embodiments, the
accumulated data is committed to a remote database. In embodiments,
the system rearranges its position in a mesh network topology with
other similarly configured systems in order to minimize the amount
of data it must relay from the other systems. In embodiments, the
system rearranges its position in a mesh network topology with
other similarly configured systems in order to minimize the amount
of data it must send through other the other systems.
[1319] In embodiments, a system for data collection in an
industrial environment having a self-sufficient data acquisition
box for capturing and analyzing data in an industrial process
comprises a data circuit for analyzing a plurality of sensor
inputs, a network control circuit for sending and receiving
information related to the sensor inputs to an external system,
where the system provides sensor data to one or more similarly
configured systems and where the system and the one or more
similarly configured systems are arranged as a consolidated virtual
information provider.
[1320] In embodiments, the system and each of the similarly
configured systems multiplex their information. In embodiments, the
system and each of the similarly configured systems provide a
single unified information source to a requestor. In embodiments,
the system and each of the similarly configured systems further
comprise an intelligent agent circuit that combines the data
between systems. In embodiments, the system and each of the
similarly configured systems further comprise an intelligent agent
circuit that chooses what data to collect or store based on a
machine learning algorithm. In embodiments, the machine learning
algorithm further comprises a feedback function that takes as input
what data is used by an external system. In embodiments, the
machine learning algorithm further comprises a control function
that adjusts the degree of precision, frequency of capture, or
information stored based on an analysis of requests for data over
time. In embodiments, the machine learning algorithm further
comprises a feedback function that adjusts what sensor data is
captured based on an analysis of requests for information over
time. In embodiments, the machine learning algorithm further
comprises a feedback function that adjusts what sensor data is
captured based on historical use of information. In embodiments,
the machine learning algorithm further comprises a feedback
function that adjusts what sensor data is captured based on what
information was most indicative of a failure mode. In embodiments,
the machine learning algorithm further comprises a feedback
function that adjusts what sensor data is captured based on
detected combinations of information coincident with a failure
mode. In embodiments, the network control circuit implements a
network of similarly configured systems using an intercommunication
protocol such as multi-hop, mesh, serial, parallel, ring, real-time
and hub-and-spoke. In embodiments, the network control circuit
self-arranges the system into network communication with similarly
configured systems using an intercommunication protocol such as
multi-hop, mesh, serial, parallel, ring, real-time and
hub-and-spoke. In embodiments, after a configurable time period,
the system stores only digests of the information and discards the
underlying information.
[1321] A system for data collection in an industrial environment
having a self-sufficient data acquisition box for capturing and
analyzing data in an industrial environment, the system comprising:
a data circuit for analyzing a plurality of sensor inputs; a
network communication interface; a network control circuit for
sending and receiving information related to the sensor inputs to
an external system; and a data filter circuit configured to
dynamically adjust what portion of the information is sent based on
instructions received over the network communication interface.
[1322] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a roller bearing
assembly selected from the group consisting of rust, micropitting,
macropitting, gear teeth breakage, fretting, case-core separation,
plastic deformation, scuffing, polishing, adhesion, abrasion,
subcase fatigue, erosion, corrosion, electric discharge,
cavitation, cracking, scoring, profile pitting, and spalling.
[1323] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a gear box selected
from the group consisting of micropitting, macropitting, gear tooth
wear, tooth breakage, spalling, fretting, case-core separation,
plastic deformation, scuffing, polishing, adhesion, abrasion,
subcase fatigue, erosion, electric discharge, cavitation, rust,
corrosion, and cracking.
[1324] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a hydraulic pump
selected from the group consisting of fluid aeration, overheating,
over-pressurization, lubricating film loss, depressurization, shaft
failure, vacuum seal failure, large particle contamination, small
particle contamination, rust, corrosion, cavitation, shaft galling,
seizure, bushing wear, channel seal loss, and implosion.
[1325] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in an engine selected
from the group consisting of imbalance, gasket failure, camshaft,
spring breakage, valve breakage, valve scuffing, valve leakage,
clutch slipping, gear interference, belt slipping, belt teeth
breakage, belt breakage, gear tooth failure, oil seal failure,
aftercooler, intercooler, or radiator failure, rod failure, sensor
failure, crankshaft failure, bearing seizure, overload at low RPM,
cranking, full stop, high RPM, overspeed, piston disintegration,
shock overload, torque overload, surface fatigue, critical speed
failure, weld failure, and material failures including
micropitting, macropitting, gear teeth breakage, fretting,
case-core separation, plastic deformation, scuffing, polishing,
adhesion, abrasion, subcase fatigue, rust, erosion, corrosion,
electric discharge, cavitation, cracking, scoring, profile pitting,
spalling.
[1326] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a vehicle chassis,
body or frame selected from the group consisting of imbalance,
gasket failure, spring breakage, lubricant seal failure, sensor
failure, bearing seizure, shock overload, surface fatigue, weld
failure, spring failure, strut failure, control arm failure,
kingpin failure, tie-rod & end failure, pinion bearing failure,
pinion gear failure, and material failures including micropitting,
macropitting, fretting, rust, erosion, corrosion, electric
discharge, cavitation, cracking, scoring, profile pitting,
spalling.
[1327] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a powertrain,
propeller shaft, drive shaft, final drive, or wheel end, selected
from the group consisting of imbalance, gasket failure, camshaft
failure, gear box failure, spring breakage, valve breakage, valve
scuffing, belt teeth breakage, belt breakage, gear tooth failure,
oil seal failure, rod failure, sensor failure, crankshaft failure,
bearing seizure, overload at low RPM, cranking, full stop, high
RPM, overspeed, piston disintegration, shock overload, torque
overload, surface fatigue, critical speed failure, yoke damage,
weld failure, u-joint failure, CV joint failure, differential
failure, axle shaft failure, spring failure, strut failure, control
arm failure, kingpin failure, tie-rod & end failure, pinion
bearing failure, ring gear failure, pinion gear failure, spider
gear failure, wheel bearing failure, and material failures
including micropitting, macropitting, gear teeth breakage,
fretting, case-core separation, plastic deformation, scuffing,
polishing, adhesion, abrasion, subcase fatigue, rust, erosion,
corrosion, electric discharge, cavitation, cracking, scoring,
profile pitting, and spalling.
[1328] Wherein the sensor inputs are selected from the group
consisting of roller bearing sensor, deformation sensor, camera,
ultraviolet sensor, infrared sensor, audio sensor, vibration
sensor, viscosity sensor, chemical sensor, contaminant sensor,
particulate sensor, weight sensor, rotation sensor, temperature
sensor, position sensor, ultrasonic sensor, solid chemical sensor,
pH sensor, fluid chemical sensor, lubricant sensor, radiation
sensor, x-ray radiograph, gamma-ray radiograph, scanning tunneling
microscope, photon tunneling microscope, scanning probe microscope,
laser displacement meter, magnetic particle inspector, ultraviolet
particle detector, load sensor, static load sensor, axial load
sensor, accelerometer, speed sensor, rotational sensor, moisture,
humidity, ammeter, voltmeter, flux meter, and electric field
detector, gear box sensor, gear wear sensor, "tooth decay" sensor,
rotation sensors, transmission input sensor, transmission output
sensor, manifold airflow sensor (determines engine load and thus
affects gearbox), engine load sensors, throttle position sensor,
coolant temperature sensor, speed sensor, brake sensor, fluid
temperature sensor, tool load sensor, bearing sensor, standstill
counter, hydraulic pump sensor, oxygen sensors, gas sensors, oil
sensors, chemical analysis, pressure detector, vacuum detector,
densitometer, torque sensor, engine sensor, exhaust sensors,
exhaust gas sensor, crankshaft position sensor, camshaft position
sensor, capacitive pressure sensor, piezo-resistive sensor,
wireless sensor, wireless pressure sensor, chemical sensors, oxygen
sensor, fuel sensor, gyro sensor, mechanical position sensors,
accelerometer, mems sensors, digital sensors, mass air flow sensor,
manifold absolute pressure sensor, throttle control sensor,
injector sensor, NOx sensor, variable valve timing sensor, tank
pressure sensor, fuel level sensor, fuel flow sensor, fluid flow
sensor, damper sensor, torque sensor, particulate sensor, air flow
meter, air temperature sensor, coolant temperature sensor,
in-cylinder pressure sensor, engine speed sensor, knock sensor,
drive shaft sensor, angular sensor, transverse vibration sensor,
torsional vibration sensor, critical speed vibration sensor,
powertrain sensor, engine sensors: power sensor, oil pressure, oil
temperature, oil viscosity, oil flow sensor, load sensor
(structural analysis), vibration sensor, frequency sensor, audio
sensor, transfer case sensor, differential sensor, tire pressure
gauge, tire damage gauge, tire vibration sensor, hub and rim
integrity sensors, air leak sensors, fluid leak sensors, and
lubricant leak sensors.
[1329] Wherein the sensor inputs additionally comprise microphones
or vibration sensors configured to detect vibrational or
audio-frequency conditions in movable or rotational components
selected from the list consisting of whirring, howling, growling,
whining, rumbling, clunking, rattling, wheel hopping,
chattering.
[1330] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a production line
gear box selected from the group consisting of micropitting,
macropitting, gear tooth wear, tooth breakage, spalling, fretting,
case-core separation, plastic deformation, scuffing, polishing,
adhesion, abrasion, subcase fatigue, erosion, electric discharge,
cavitation, corrosion, and cracking.
[1331] Wherein the data circuit is configured to analyze data
indicative of a fatigue or wear failure mode in a production line
vibrator selected from the group consisting of moisture
penetration, contamination, micropitting, macropitting, gear tooth
wear, tooth breakage, spalling, fretting, case-core separation,
plastic deformation, scuffing, polishing, adhesion, abrasion,
subcase fatigue, rust, erosion, electric discharge, cavitation,
corrosion, and cracking.
[1332] Wherein the analyzing further comprises detecting anomalies
in the received data.
[1333] Wherein the data filter circuit executes stored procedures
to create digests of the information.
[1334] Wherein the system discards the data underlying the digests
of the information after a user-configurable time period.
[1335] Wherein the analyzing further comprises determining what
data to store, determining what data to transmit, determining what
data to summarize, determining what data to discard, or determining
the accuracy of the received data.
[1336] Wherein the system is configured to communicate with a
plurality of other similarly configured systems and store the
information when the amount of storage used by the system exceeds a
threshold.
[1337] Wherein the system is configured to execute the instructions
received via the network communication interface using a virtual
machine.
[1338] Wherein the system further comprises a digitally signed code
execution environment to decrypt and run the instructions it
receives via the network interface.
[1339] Wherein the system further comprises multiple distinct
cryptographically protected memory segments.
[1340] Wherein the at least one of the memory segments is made
available for public interaction with the stored data via a public
key-private key management system.
[1341] Wherein the system further comprises a conditioning circuit
for converting signals to a form suitable for input to an
analog-to-digital converter.
[1342] A system for data collection in an industrial environment
having a self-sufficient data acquisition box for capturing and
analyzing data in an industrial process, the system comprising:
a data circuit for analyzing a plurality of sensor inputs; a
network control circuit for sending and receiving information
related to the sensor inputs to an external system; a storage
device; where the data circuit continuously monitors sensor inputs
and stores them in an embedded data cube; and where the data
acquisition box dynamically determines what information to send
based on statistical analysis of historical data.
[1343] Wherein the system further comprises a plurality of network
communication interfaces.
[1344] Wherein the network control circuit bridges another
similarly configured system from one network to another using the
plurality of network communication interfaces.
[1345] Wherein the analyzing further comprises detecting anomalies
in the information.
[1346] Wherein the data circuit executes stored procedures to
create digests of the information.
[1347] Wherein the data circuit supplies digest data to one client
and non-digest data to another client simultaneously.
[1348] Wherein the data circuit stores digests of historical
anomalies and discards at least a portion of the information.
[1349] Wherein the data circuit provides client query access to the
embedded data cube in real time.
[1350] Wherein the data circuit supports client requests in the
form of a SQL query.
[1351] Wherein the data circuit supports client requests in the
form of a OLAP query.
[1352] Wherein the system further comprises a conditioning circuit
for converting signals to a form suitable for input to an
analog-to-digital converter.
[1353] A system for data collection in an industrial environment
having a self-sufficient data acquisition box for capturing and
analyzing data in an industrial process, the system comprising:
a data circuit for analyzing a plurality of sensor inputs; a
network control circuit for sending and receiving information
related to the sensor inputs to an external system; wherein the
system is configured to provide sensor data to a plurality of other
similarly configured systems; and wherein the system dynamically
reconfigures where it sends data and the and the quantity it sends
based on the availability of the other similarly configured
systems.
[1354] Wherein the system further comprises a plurality of network
communication interfaces.
[1355] Wherein the network control circuit bridges another
similarly configured system from one network to another using the
plurality of network communication interfaces.
[1356] Wherein the dynamic reconfiguration is based on requests
received over the one or more network communication interfaces.
[1357] Wherein the dynamic reconfiguration is based on requests
made by a remote user.
[1358] Wherein the dynamic reconfiguration is based on an analysis
of the type of data acquired by the data acquisition box.
[1359] Wherein the dynamic reconfiguration is based on an operating
parameter of at least one of the system and one of the similarly
configured systems.
[1360] Wherein the network control circuit sends sensor data in
packets designed to be stored and forwarded by the other similarly
configured systems.
[1361] Wherein, when a fault is detected in the system, the network
control circuit forwards a at least a portion of its stored
information for to another similarly configured system.
[1362] Wherein the network control circuit determines how to route
information through a network of similarly configured systems
connected, based on the source of the information request.
[1363] Wherein the network control circuit decides how to route
data in a network of similarly configured systems, based on how
frequently information is being requested.
[1364] Wherein the decides how to route data in a network of
similarly configured systems, based how much data is being
requested over a given period.
[1365] Wherein the network control circuit implements a network of
similarly configured systems using an intercommunication protocol
selected from the list consisting of multi-hop, mesh, serial,
parallel, ring, real-time and hub-and-spoke.
[1366] Wherein, after a configurable time period, the system stores
only digests of the information and discards the underlying
information.
[1367] Wherein the system further comprises a conditioning circuit
for converting signals to a form suitable for input to an
analog-to-digital converter.
[1368] A system for data collection in an industrial environment
having a self-sufficient data acquisition box for capturing and
analyzing data in an industrial process, the system comprising:
a data circuit for analyzing a plurality of sensor inputs; a
network control circuit for sending and receiving information
related to the sensor inputs to an external system; wherein the
system provides sensor data to one or more similarly configured
systems; wherein the data circuit dynamically reconfigures the
route by which it sends data based on how many other devices are
requesting the information.
[1369] Wherein the system further comprises a plurality of network
communication interfaces.
[1370] Wherein the network control circuit bridges another
similarly configured system from one network to another using the
plurality of network communication interfaces.
[1371] Where the network control circuit implements a network of
similarly configured systems using an intercommunication protocol
selected from the list consisting of multi-hop, mesh, serial,
parallel, ring, real-time and hub-and-spoke.
[1372] Wherein the system continuously provides a single copy of
its information to another similarly configured system and directs
requesters of its information to the another similarly configured
system.
[1373] Wherein the another similarly configured system has
different operational characteristics than the system.
[1374] Wherein different operational characteristics are selected
from the list consisting of power, storage, network connectivity,
proximity, reliability, duty cycle.
[1375] Wherein, after a configurable time period, the system stores
only digests of the information and discards the underlying
information.
[1376] A system for data collection in an industrial environment
having a self-sufficient data acquisition box for capturing and
analyzing data in an industrial process, the system comprising:
a data circuit for analyzing a plurality of sensor inputs; a
network control circuit for sending and receiving information
related to the sensor inputs to an external system; wherein the
system provides sensor data to one or more similarly configured
systems; and wherein the data circuit dynamically nominates a
similarly configured system capable of providing sensor data to
replace the system.
[1377] Wherein the nomination is triggered by the detection of a
system failure mode.
[1378] Wherein, when the system is unable to supply a requested
signal it nominates another similarly configured system to supply
similar but not identical information to a requestor.
[1379] Wherein the system indicates to the requestor that the new
signal is different than the original.
[1380] Where the network control circuit implements a network of
similarly configured systems using an intercommunication protocol
selected from the list consisting of multi-hop, mesh, serial,
parallel, ring, real-time and hub-and-spoke.
[1381] Wherein, after a configurable time period, the system stores
only digests of the information and discards the underlying
information.
[1382] Wherein the network control circuit self-arranges the system
into a redundant storage network with one or more similarly
configured systems.
[1383] Wherein the network control circuit self-arranges the system
into a fault-tolerant storage network with one or more similarly
configured systems.
[1384] Wherein the network control circuit self-arranges the system
into a hierarchical storage network with one or more similarly
configured systems.
[1385] Wherein the network control circuit self-arranges the system
into a hierarchical data transmission configuration in order to
reduce upstream traffic.
[1386] Wherein the network control circuit self-arranges the system
into a matrixed network configuration with multiple redundant data
paths in order to increase reliability of information
transmission.
[1387] Wherein the network control circuit self-arranges the system
into a matrixed network configuration with multiple redundant data
paths in order to increase reliability of information
transmission.
[1388] Wherein the system accumulates data received from other
similarly configured systems while an upstream network connection
is unavailable, and then sends all accumulated data once the
upstream network connection is restored.
[1389] Wherein the accumulated data is committed to a remote
database.
[1390] Wherein the system rearranges its position in a mesh network
topology with other similarly configured systems in order to
minimize the amount of data it must relay from the other
systems.
[1391] Wherein the system rearranges its position in a mesh network
topology with other similarly configured systems in order to
minimize the amount of data it must send through other the other
systems.
[1392] A system for data collection in an industrial environment
having a self-sufficient data acquisition box for capturing and
analyzing data in an industrial process, the system comprising:
a data circuit for analyzing a plurality of sensor inputs; a
network control circuit for sending and receiving information
related to the sensor inputs to an external system; wherein the
system provides sensor data to one or more similarly configured
systems; and wherein the system and the one or more similarly
configured systems are arranged as a consolidated virtual
information provider.
[1393] Wherein the system and each of the similarly configured
systems multiplex their information.
[1394] Wherein the system and each of the similarly configured
systems provide a single unified information source to a
requestor.
[1395] Wherein the system and each of the similarly configured
systems further comprise an intelligent agent circuit that combines
the data between systems.
[1396] Wherein the system and each of the similarly configured
systems further comprise an intelligent agent circuit that chooses
what data to collect or store based on a machine learning
algorithm.
[1397] Wherein the machine learning algorithm further comprises a
feedback function that takes as input what data is used by an
external system.
[1398] Wherein the machine learning algorithm further comprises a
control function that adjusts the degree of precision, frequency of
capture, or information stored based on an analysis of requests for
data over time.
[1399] Wherein the machine learning algorithm further comprises a
feedback function that adjusts what sensor data is captured based
on an analysis of requests for information over time.
[1400] Wherein the machine learning algorithm further comprises a
feedback function that adjusts what sensor data is captured based
on historical use of information.
[1401] Wherein the machine learning algorithm further comprises a
feedback function that adjusts what sensor data is captured based
on what information was most indicative of a failure mode.
[1402] Wherein the machine learning algorithm further comprises a
feedback function that adjusts what sensor data is captured based
on detected combinations of information coincident with a failure
mode.
[1403] Wherein the network control circuit implements a network of
similarly configured systems using an intercommunication protocol
selected from the list consisting of multi-hop, mesh, serial,
parallel, ring, real-time and hub-and-spoke.
[1404] Wherein the network control circuit self-arranges the system
into network communication with similarly configured systems using
an intercommunication protocol selected from the list consisting of
multi-hop, mesh, serial, parallel, ring, real-time and
hub-and-spoke.
[1405] Wherein, after a configurable time period, the system stores
only digests of the information and discards the underlying
information.
[1406] Disclosed herein are methods and systems for data collection
in an industrial environment featuring self-organization
functionality. Such data collection systems and methods may
facilitate intelligent, situational, context-aware collection,
summarization, storage, processing, transmitting, and/or
organization of data, such as by one or more data collectors (such
as any of the wide range of data collector embodiments described
throughout this disclosure), a central headquarters or computing
system, and the like. The described self-organization functionality
of data collection in an industrial environment may improve various
parameters of such data collection, as well as parameters of the
processes, applications, and products that depend on data
collection, such as data quality parameters, consistency
parameters, efficiency parameters, comprehensiveness parameters,
reliability parameters, effectiveness parameters, storage
utilization parameters, yield parameters (including financial
yield, output yield, and reduction of adverse events), energy
consumption parameters, bandwidth utilization parameters,
input/output speed parameters, redundancy parameters, security
parameters, safety parameters, interference parameters,
signal-to-noise parameters, statistical relevancy parameters, and
others. The self-organization functionality may optimize across one
or more such parameters, such as based on a weighting of the value
of the parameters; for example, a swarm of data collectors may be
managed (or manage itself) to provide a given level of redundancy
for critical data, while not exceeding a specified level of energy
usage, e.g., per data collector or a group of data collectors or
the entire swarm of data collectors. This may include using a
variety of optimization techniques described throughout this
disclosure and the documents incorporated herein by reference.
[1407] In embodiments, such methods and systems for data collection
in an industrial environment can include one or more data
collectors, e.g., arranged in a cooperative group or "swarm" of
data collectors, that collect and organize data in conjunction with
a data pool in communication with a computing system, as well as
supporting technology components, services, processes, modules,
applications and interfaces, for managing the data collection
(collectively referred to in some cases as a data collection system
12004). Examples of such components include, but are not limited
to, a model-based expert system, a rule-based expert system, an
expert system using artificial intelligence (such as a machine
learning system, which may include a neural net expert system, a
self-organizing map system, a human-supervised machine learning
system, a state determination system, a classification system, or
other artificial intelligence system), or various hybrids or
combinations of any of the above. References to a self-organizing
method or system should be understood to encompass utilization of
any one of the foregoing or suitable combinations, except where
context indicates otherwise.
[1408] The data collection systems and methods of the present
disclosure can be utilized with various types of data, including
but not limited to vibration data, noise data and other sensor data
of the types described throughout this disclosure. Such data
collection can be utilized for event detection, state detection,
and the like, and such event detection, state detection, and the
like can be utilized to self-organize the data collection systems
and methods, as further discussed herein. The self-organization
functionality may include managing data collector(s), both
individually or in groups, where such functionality is directed at
supporting an identified application, process, or workflow, such as
confirming progress toward or/alignment with one or more
objectives, goals, rules, policies, or guidelines. The
self-organization functionality may also involve managing a
different goal/guideline, or directing data collectors targeted to
determining an unknown variable based on collection of other data
(such as based on a model of the behavior of a system that involves
the variable), selecting preferred sensor inputs among available
inputs (including specifying combinations, fusions, or multiplexing
of inputs), and/or specifying a specific data collector among
available data collectors.
[1409] A data collector may include any number of items, such as
sensors, input channels, data locations, data streams, data
protocols, data extraction techniques, data transformation
techniques, data loading techniques, data types, frequency of
sampling, placement of sensors, static data points, metadata,
fusion of data, multiplexing of data, self-organizing techniques,
and the like as described herein. Data collector settings may
describe the configuration and makeup of the data collector, such
as by specifying the parameters that define the data collector. For
example, data collector settings may include one or more
frequencies to measure. Frequency data may further include at least
one of a group of spectral peaks, a true-peak level, a crest factor
derived from a time waveform, and an overall waveform derived from
a vibration envelope, as well as other signal characteristics
described throughout this disclosure. Data collectors may include
sensors measuring or data regarding one or more wavelengths, one or
more spectra, and/or one or more types of data from various sensors
and metadata. Data collectors may include one or more sensors or
types of sensors of a wide range of types, such as described
throughout this disclosure and the documents incorporated by
reference herein. Indeed, the sensors described herein may be used
in any of the methods or systems described throughout this
disclosure. For example, one sensor may be an accelerometer, such
as one that measures voltage per G of acceleration (e.g., 100 mV/G,
500 mV/G, 1 V/G, 5 V/G, 10 V/G). In embodiments, a data collector
may alter the makeup of the subset of the plurality of sensors used
in a data collector based on optimizing the responsiveness of the
sensor, such as for example choosing an accelerometer better suited
for measuring acceleration of a lower speed gear system or
drill/boring device versus one better suited for measuring
acceleration of a higher speed turbine in a power generation
environment. Choosing may be done intelligently, such as for
example with a proximity probe and multiple accelerometers disposed
on a specific target (e.g., a gear system, drill, or turbine) where
while at low speed one accelerometer is used for measuring in the
data collector and another is used at high speeds. Accelerometers
come in various types, such as piezo-electric crystal, low
frequency (e.g., 10 V/G), high speed compressors (10 MV/G), MEMS,
and the like. In another example, one sensor may be a proximity
probe which can be used for sleeve or tilt-pad bearings (e.g., oil
bath), or a velocity probe. In yet another example, one sensor may
be a solid state relay (SSR) that is structured to automatically
interface with another routed data collector (such as a mobile or
portable data collector) to obtain or deliver data. In another
example, a data collector may be routed to alter the makeup of the
plurality of available sensors, such as by bringing an appropriate
accelerometer to a point of sensing, such as on or near a component
of a machine. In still another example, one sensor may be a triax
probe (e.g., a 100 MV/G triax probe), that in embodiments is used
for portable data collection. In some embodiments, of a triax
probe, a vertical element on one axis of the probe may have a high
frequency response while the ones mounted horizontally may
influence limit the frequency response of the whole triax. In
another example, one sensor may be a temperature sensor and may
include a probe with a temperature sensor built inside, such as to
obtain a bearing temperature. In still additional examples, sensors
may be ultrasonic, microphone, touch, capacitive, vibration,
acoustic, pressure, strain gauges, thermographic (e.g., camera),
imaging (e.g., camera, laser, IR, structured light), afield
detector, an EMI' meter to measure an AC electromagnetic field, a
gaussmeter, a motion detector, a chemical detector, a gas detector,
a CBRNE detector, a vibration transducer, a magnetometer,
positional, location-based, a velocity sensor, a displacement
sensor, a tachometer, a flow sensor, a level sensor, a proximity
sensor, a pH sensor, a hygrometer/moisture sensor, a densitometric
sensor, an anemometer, a viscometer, or any analog industrial
sensor and/or digital industrial sensor. In a further example,
sensors may be directed at detecting or measuring ambient noise,
such as a sound sensor or microphone, an ultrasound sensor, an
acoustic wave sensor, and an optical vibration sensor (e.g., using
a camera to see oscillations that produce noise). In still another
example, one sensor may be a motion detector.
[1410] Data collectors may be of or may be configured to encompass
one or more frequencies, wavelengths or spectra for particular
sensors, for particular groups of sensors, or for combined signals
from multiple sensors (such as involving multiplexing or sensor
fusion). Data collectors may be of or may be configured to
encompass one or more sensors or sensor data (including groups of
sensors and combined signals) from one or more pieces of
equipment/components, areas of an installation, disparate but
interconnected areas of an installation (e.g., a machine assembly
line and a boiler room used to power the line), or locations (e.g.,
a building in one geographic location and a building in a separate,
different geographic location). Data collector settings,
configurations, instructions, or specifications (collectively
referred to herein using any one of those terms) may include where
to place a sensor, how frequently to sample a data point or points,
the granularity at which a sample is taken (e.g., a number of
sampling points per fraction of a second), which sensor of a set of
redundant sensors to sample, an average sampling protocol for
redundant sensors, and any other aspect that would affect data
acquisition.
[1411] Within the data collection system 12004, the
self-organization functionality can be implemented by a neural net,
a model-based system, a rule-based system, a machine learning
system, and/or a hybrid of any of those systems. Further, the
self-organizing functionality may be performed in whole or in part
by individual data collectors, a collection or group of data
collectors, a network-based computing system, a local computing
system comprising one or more computing devices, a remote computing
system comprising one or more computing devices, and a combination
of one or more of these components. The self-organization
functionality may be optimized for a particular goal or outcome,
such as predicting and managing performance, health, or other
characteristics of a piece of equipment, a component, or a system
of equipment or components. Based on continuous or periodic
analysis of sensor data, as patterns/trends are identified, or
outliers appear, or a group of sensor readings begin to change,
etc., the self-organization functionality may modify the collection
of data intelligently, as described herein. This may occur by
triggering a rule that reflects a model or understanding of system
behavior (e.g., recognizing a shift in operating mode that calls
for different sensors as velocity of a shaft increases) or it may
occur under control of a neural net (either in combination with a
rule-based approach or on its own), where inputs are provided such
that the neural net over time learns to select appropriate
collection modes based on feedback as to successful outcomes (e.g.,
successful classification of the state of a system, successful
prediction, successful operation relative to a metric). For example
only, when an assembly line is reconfigured for a new product or a
new assembly line is installed in a manufacturing facility, data
from the current data collector(s) may not accurately predict the
state or metric of operation of the system, thus, the
self-organization functionality may begin to iterate to determine
if a new data collector, type of sensed data, format of sensed
data, etc. is better at predicting a state or metric. Based on
offset system data, such as from a library or other data structure,
certain sensors, frequency bands or other data collectors may be
used in the system initially and data may be collected to assess
performance. As the self-organization functionality iterates, other
sensors/frequency bands may be accessed to determine their relative
weight in identifying performance metrics. Over time, a new
frequency band may be identified (or a new collection of sensors, a
new set of configurations for sensors, or the like) as a better or
more suitable gauge of performance in the system and the
self-organization functionality may modify its data collector(s)
based on this iteration. For example only, perhaps an older boring
tool in an energy extraction environment dampens one or more
vibration frequencies while a different frequency is of higher
amplitude and present during optimal performance than what was seen
in the present system. In this example, the self-organization
functionality may alter the data collectors from what was
originally proposed, e.g., by the data collection system, to
capture the higher amplitude frequency that is present in the
current system.
[1412] The self-organization functionality, in embodiments
involving a neural net or other machine learning system, may be
seeded and may iterate, e.g., based on feedback and operation
parameters, such as described herein. Certain feedback may include
utilization measures, efficiency measures (e.g., power or energy
utilization, use of storage, use of bandwidth, use of input/output
use of perishable materials, use of fuel, and/or financial
efficiency, financial such as reduction of costs), measures of
success in prediction or anticipation of states (e.g., avoidance
and mitigation of faults), productivity measures (e.g., workflow),
yield measures, and profit measures. Certain parameters may include
storage parameters (e.g., data storage, fuel storage, storage of
inventory), network parameters (e.g., network bandwidth,
input/output speeds, network utilization, network cost, network
speed, network availability), transmission parameters (e.g.,
quality of transmission of data, speed of transmission of data,
error rates in transmission, cost of transmission), security
parameters (e.g., number and/or type of exposure events,
vulnerability to attack, data loss, data breach, access
parameters), location and positioning parameters (e.g., location of
data collectors, location of workers, location of machines and
equipment, location of inventory units, location of parts and
materials, location of network access points, location of ingress
and egress points, location of landing positions, location of
sensor sets, location of network infrastructure, location of power
sources), input selection parameters, data combination parameters
(e.g., for multiplexing, extraction, transformation, loading),
power parameters (e.g., of individual data collectors, groups of
data collectors, or all potentially available data collectors),
states (e.g., operational modes, availability states, environmental
states, fault modes, health states, maintenance modes, anticipated
states), events, and equipment specifications. With respect to
states, operating modes may include, mobility modes (direction,
speed, acceleration, and the like), type of mobility modes (e.g.,
rolling, flying, sliding, levitation, hovering, floating),
performance modes (e.g., gears, rotational speeds, heat levels,
assembly line speeds, voltage levels, frequency levels), output
modes, fuel conversion modes, resource consumption modes, and
financial performance modes (e.g., yield, profitability).
Availability states may refer to anticipating conditions that could
cause machine to go offline or require backup. Environmental states
may refer to ambient temperature, ambient humidity/moisture,
ambient pressure, ambient wind/fluid flow, presence of pollution or
contaminants, presence of interfering elements (e.g., electrical
noise, vibration), power availability, and power quality, among
other parameters. Anticipated states may include achieving or not
achieving a desired goal, such as a specified/threshold output
production rate, a specified/threshold generation rate, an
operational efficiency/failure rate, a financial efficiency/profit
goal, a power efficiency/resource utilization, an avoidance of a
fault condition (e.g., overheating, slow performance, excessive
speed, excessive motion, excessive vibration/oscillation, excessive
acceleration, expansion/contraction, electrical failure, running
out of stored power/fuel, overpressure, excessive radiation/melt
down, fire, freezing, failure of fluid flow (e.g., stuck valves,
frozen fluids), mechanical failures (e.g., broken component, worn
component, faulty coupling, misalignment, asymmetries/deflection,
damaged component (e.g., deflection, strain, stress, cracking),
imbalances, collisions, jammed elements, and lost or slipping chain
or belt), avoidance of a dangerous condition or catastrophic
failure, and availability (online status)).
[1413] The self-organization functionality may comprise or be
seeded with a model that predicts an outcome or state given a set
of data, which may comprise inputs from sensors, such as via a data
collector, as well as other data, such as from system components,
from external systems and from external data sources. For example,
the model may be an operating model for an industrial environment,
machine, or workflow. In another example, the model may be for
anticipating states, for predicting fault, for optimizing
maintenance, for optimizing data transport (such as for optimizing
network coding, network-condition-sensitive routing), for
optimizing data marketplaces, and the like.
[1414] The self-organization functionality may result in any number
of downstream actions based on analysis of data from the data
collector(s). In an embodiment, the self-organization functionality
may determine that the system should either keep or modify
operational parameters, equipment or a weighting of a neural net
model given a desired goal, such as a specified/threshold output
production rate, specified/threshold generation rate, an
operational efficiency/failure rate, a financial efficiency/profit
goal, a power efficiency/resource utilization, an avoidance of a
fault condition, an avoidance of a dangerous condition or
catastrophic failure, and the like. In embodiments, the adjustments
may be based on determining context of an industrial system, such
as understanding a type of equipment, its purpose, its typical
operating modes, the functional specifications for the equipment,
the relationship of the equipment to other features of the
environment (including any other systems that provide input to or
take input from the equipment), the presence and role of operators
(including humans and automated control systems), and ambient or
environmental conditions. For example, in order to achieve a profit
goal in a distribution environment (e.g., a power distribution
environment), a generator or system of generators may need to
operate at a certain efficiency level. The self-organization
functionality may be seeded with a model for operation of the
system of generators in a manner that results in a specified profit
goal, such as indicating an on/off state for individual
generator(s) in the power generation system based on the time of
day, current market sale price for the fuel consumed by the
generators, current demand or anticipated future demand, and the
like. As it acquires data and iterates, the model predicts whether
the profit goal will be achieved given the current data, and
determine whether the data or type of data being collected is
appropriate, sufficient, etc. for the model. Based on the results
of the iteration, a recommendation may be made (or a control
instruction may be automatically provided) to gather
different/additional data, organize the data differently, direct
different data collectors to collect new data, etc. and/or to
operate a subset of the generators at a higher output (but less
efficient) rate, power on additional generators, maintain a current
operational state, or the like. Further, as the system iterates,
one or more additional sensors may be sampled in the model to
determine if their addition to the self-organization functionality
would improve predicting a state or otherwise assisting with the
goals of the data collection efforts.
[1415] In embodiments, a system for data collection in an
industrial environment may include a plurality of input sensors,
such as any of those described herein, communicatively coupled to a
data collector having one or more processors. The data collection
system may include a plurality of individual data collectors
structured to operate together to determine at least one subset of
the plurality of sensors from which to process output data. The
data collection system may also include a machine learning circuit
structured to receive output data from the at least one subset of
the plurality of sensors and learn received output data patterns
indicative of a state. In some embodiments, the data collection
system may alter the at least one subset of the plurality of
sensors, or an aspect thereof, based on one or more of the learned
received output data patterns and the state. In certain
embodiments, the machine learning circuit is seeded with a model
that enables it to learn data patterns. The model may be a physical
model, an operational model, a system model, and the like. In other
embodiments, the machine learning circuit is structured for deep
learning wherein input data is fed to the circuit with no or
minimal seeding and the machine learning data analysis circuit
learns based on output feedback. For example, a metal tooling
system in a manufacturing environment may operate to manufacture
parts using machine tools such as lathes, milling machines,
grinding machines, boring tools, and the like. Such machines may
operate at various speeds and output rates, which may affect the
longevity, efficiency, accuracy, etc. of the machine. The data
collector may acquire various parameters to evaluate the
environment of the machine tools, e.g., speed of operation, heat
generation, vibration, and conformity with a part specification.
The system can utilize such parameters and iterate towards a
prediction of state, output rate, etc. based on such feedback.
Further, the system may self-organize such that the data
collector(s) collect additional/different data from which such
predictions may be made.
[1416] There may be a balance of multiple goals/guidelines in the
self-organization functionality of data collection system. For
example, a repair and maintenance organization (RMO) may have
operating parameters designed for maintenance of a machine in a
manufacturing facility, while the owner of the facility may have
particular operating parameters for the machine that are designed
for meeting a production goal. These goals, in this example
relating to a maintenance goal or a production output, may be
tracked by a different data collectors or sensors. For example,
maintenance of a machine may be tracked by sensors including a
temperature sensor, a vibration transducer, and a strain gauge
while the production goal of a machine may be tracked by sensors
including a speed sensor and a power consumption meter. The data
collection system may (optionally using a neural net, machine
learning system, deep learning system, or the like, which may occur
under supervision by one or more supervisors (human or automated)
intelligently manage data collectors aligned with different goals
and assign weights, parameter modifications, or recommendations
based on a factor, such as a bias towards one goal or a compromise
to allow better alignment with all goals being tracked, for
example. Compromises among the goals delivered to the data
collection system may be based on one or more hierarchies or rules
relating to the authority, role, criticality, or the like of the
applicable goals. In embodiments, compromises among goals may be
optimized using machine learning, such as a neural net, deep
learning system, or other artificial intelligence system as
described throughout this disclosure. For example, in a power plant
where a turbine is operating, the data collection system may manage
multiple data collectors, such as one directed to detecting the
operational status of the turbine, one directed at identifying a
probability of hitting a production goal, and one directed at
determining if the operation of the turbine is meeting a fuel
efficiency goal. Each of these data collectors may be populated
with different sensors or data from different sensors (e.g., a
vibration transducer to indicate operational status, a flow meter
to indicate production goal, and a fuel gauge to indicate a fuel
efficiency) whose output data are indicative of an aspect of a
particular goal. Where a single sensor or a set of sensors is
helpful for more than one goal, overlapping data collectors (having
some sensors in common and other sensors not in common) may take
input from that sensor or set of sensors, as managed by the data
collection system. If there are constraints on data collection
(such as due to power limitations, storage limitations, bandwidth
limitations, input/output processing capabilities, or the like), a
rule may indicate that one goal (e.g., a fuel utilization goal or a
pollution reduction goal that is mandated by law or regulation)
takes precedence, such that the data collection for the data
collectors associated with that goal are maintained as others are
paused or shut down. Management of prioritization of goals may be
hierarchical or may occur by machine learning. The data collection
system may be seeded with models, or may not be seeded at all, in
iterating towards a predicted state (e.g., meeting a goal) given
the current data it has acquired. In this example, during operation
of the turbine the plant owner may decide to bias the system
towards fuel efficiency. All of the data collectors may still be
monitored, but as the self-organization functionality iterates and
predicts that the system will not collect or is not collecting data
sufficient to determine whether the system is or is not meeting a
particular goal, the data collection system may recommend or
implement changes directed at collecting the appropriate data.
Further, the plant owner may structure the system with a bias
towards a particular goal such that the recommended changes to data
collection parameters affecting such goal are made in favor of
making other recommended changes.
[1417] In embodiments, the data collection system may continue
iterating in a deep-learning fashion to arrive at a distribution of
data collectors, after being seeded with more than one data
collection data type, that optimizes meeting more than one goal.
For example, there may be multiple goals tracked for a refining
environment, such as refining efficiency and economic efficiency.
Refining efficiency for the refining system may be expressed by
comparing fuel put into the system, which can be obtained by
knowing the amount of and quality of the fuel being used, and the
amount of the refined product output from the system, which is
calculated using the flow out of the system. Economic efficiency of
the refining system may be expressed as the ratio between costs to
run the system, including fuel, labor, materials and services, and
the refined product output from the system for a period of time.
Data used to track refining efficiency may include data from a flow
meter, quality data point(s), and a thermometer, and data used to
track economic efficiency may be a flow of product output from the
system and costs data. These data may be used in the data
collection system to predict states; however, the self-organization
functionality of the system may iterate towards a data collection
strategy that is optimized to predict states related to both
thermal and economic efficiency. The new data collection schema may
include data used previously in the individual data collectors but
may also use new data from different sensors or data sources.
[1418] The iteration of the data collection system may be governed
by rules, in some embodiments. For example, the data collection
system may be structured to collect data for seeding at a
pre-determined frequency. The data collection system may be
structured to iterate at least a number of times, such as when a
new component/equipment/fuel source is added, when a sensor goes
off-line, or as standard practice. For example, when a sensor
measuring the rotation of a boring tool in an offshore drilling
operation goes off-line and the data collection system begins
acquiring data from a new sensor or data collector measuring the
same data points, the data collection system may be structured to
iterate for a number of times before the state is utilized in or
allowed to affect any downstream actions. The data collection
system may be structured to train off-line or train in situ/online.
The data collection system may be structured to include static
and/or manually input data in its data collectors. For example, a
data collection system associated with such a boring tool may be
structured to iterate towards predicting a distance bored based on
a duration of operation, wherein the data collector(s) include data
regarding the speed of the boring tools, a distance sensor, a
temperature sensor, and the like.
[1419] In embodiments, the data collection system may be overruled.
In embodiments, the data collection system may revert to prior
settings, such as in the event the self-organization functionality
fails, such as if the collected data is insufficient or
inappropriately collected, if uncertainty is too high in a
model-based system, if the system is unable to resolve conflicting
rules in rule-based system, or the system cannot converge on a
solution in any of the foregoing. For example, sensor data on a
power generation system used by the data collection system may
indicate a non-operational state (such as a seized turbine), but
output sensors and visual inspection, such as by a drone, may
indicate normal operation. In this event, the data collection
system may revert to an original data collection schema for seeding
the self-organization functionality. In another example, one or
more point sensors on a refrigeration system may indicate imminent
failure in a compressor, but the data collector self-organized to
collect data associated towards determining a performance metric
did not identify the failure. In this event, the data collector(s)
will revert to an original setting or a version of the data
collector setting that would have also identified the imminent
failure of the compressor.
[1420] In embodiments, the data collection system may change data
collector settings in the event that a new component is added that
makes the system closer to a different system. For example, a
vacuum distillation unit is added to an oil and gas refinery to
distill naphthalene, but the current data collector settings for
the data collection system are derived from a refinery that
distills kerosene. In this example, a data structure with data
collector settings for various systems may be searched for a system
that is more closely matched to the current system. When a new
system is identified as more closely matched, such as one that also
distill naphthalene, the new data collector settings (which sensors
to use, where to direct them, how frequently to sample, what types
of data and points are needed, etc. as described herein) are used
to seed the data collection system to iterate towards predicting a
state for the system. In embodiments, the data collection system
may change data collector settings in the event that a new set of
data is available from a third party library. For example, a power
generation plant may have optimized a specific turbine model to
operate in a highly efficient way and deposited the data collector
settings in a data structure. The data structure may be
continuously scanned for new data collectors that better aid in
monitoring power generation and thus, result in optimizing the
operation of the turbine.
[1421] In embodiments, the data collection system may utilize
self-organization functionality to uncover unknown variables. For
example, the data collection system may iterate to identify a
missing variable to be used for further iterations. For example, an
under-utilized tank in a legacy condensate/make-up water system of
a power station may have an unknown capacity because it is
inaccessible and no documentation exists on the tank. Various
aspects of the tank may be measured by a swarm of data collectors
to arrive at an estimated volume (e.g., flow into a downstream
space, duration of a dye traced solution to work through the
system), which can then be fed into the data collection system as a
new variable.
[1422] In embodiments, the data collection system node may be on a
machine, on a data collector (or a group of them), in a network
infrastructure (enterprise or other), or in the cloud. In
embodiments, there may be distributed neurons across nodes (e.g.,
machine, data collector, network, cloud).
[1423] In an aspect, and as illustrated in FIG. 164, a data
collection system 12004 can be arranged to collect data in an
industrial environment 12000, e.g., from one or more targets 12002.
In the illustrated embodiments, the data collection system 12004
includes a group or "swarm" 12006 of data collectors 12008, a
network 12010, a computing system 12012, and a database or data
pool 12014. Each of the data collectors 12008 can include one or
more input sensors and be communicatively coupled to any and all of
the other components of the data collection system 12004, as is
partially illustrated by the connecting arrows between
components.
[1424] The targets 12002 can be any form of machinery or component
thereof in an industrial environment 12000. Examples of such
industrial environments 12000 include but are not limited to
factories, pipelines, construction sites, ocean oil rigs, ships,
airplanes or other aircraft, mining environments, drilling
environments, refineries, distribution environments, manufacturing
environments, energy source extraction environments, offshore
exploration sites, underwater exploration sites, assembly lines,
warehouses, power generation environments, and hazardous waste
environments, each of which may include one or more targets 12002.
Targets 12002 can take any form of item or location at which a
sensor can obtain data. Examples of such targets 12002 include but
are not limited to machines, pipelines, equipment, installations,
tools, vehicles, turbines, speakers, lasers, automatons, computer
equipment, industrial equipment, and switches.
[1425] The self-organization functionality of the data collection
system 12004 can be performed at or by any of the components of the
data collection system 12004. In embodiments, a data collector
12008 or the swarm 12006 of data collectors 12008 can self-organize
without assistance from other components and based on, e.g., the
data sensed by its associated sensors and other knowledge. In
embodiments, the network 12010 can self-organize without assistance
from other components and based on, e.g., the data sensed by the
data collectors 12008 or other knowledge. Similarly, the computing
system 12012 and/or the data pool 12014 without assistance from
other components and based on, e.g., the data sensed by the data
collectors 12008 or other knowledge. It should be appreciated that
any combination or hybrid-type self-organization system can also be
implemented.
[1426] For example only, the data collection system 12004 can
perform or enable various methods or systems for data collection
having self-organization functionality in an industrial environment
12000. These methods and systems can include analyzing a plurality
of sensor inputs, e.g., received from or sensed by sensors at the
data collector(s) 12008. The methods and systems can also include
sampling the received data and self-organizing at least one of: (i)
a storage operation of the data; (ii) a collection operation of
sensors that provide the plurality of sensor inputs, and (iii) a
selection operation of the plurality of sensor inputs.
[1427] In aspects, the storage operation can include storing the
data in a local database, e.g., of a data collector 12008, a
computing system 12012, and/or a data pool 12014. The data can also
be summarized over a given time period to reduce a size of the
sensed data. The summarized data can be sent to one or more data
acquisition boxes, to one or more data centers, and/or to other
components of the system or other, separate systems. Summarizing
the data over a given time period to reduce the size of the data,
in some aspects, can include determining a speed at which data can
be sent via a network (e.g., network 12010), wherein the size of
the summarized data corresponds to the speed at which data can be
sent continuously in real time via the network. In such aspects, or
others, the summarized data can be continuously sent, e.g., to an
external device via the network.
[1428] In various implementations, the methods and systems can
include committing the summarized data to a local ledger,
identifying one or more other accessible signal acquisition
instruments on an accessible network, and/or synchronizing the
summarized data at the local ledger with at least one of the other
accessible signal acquisition instruments (e.g., data collectors
12008). In embodiments, receiving a remote stream of sensor data
from one or more other accessible signal acquisition instruments
via a network can be included. An advertisement message to a
potential client indicating availability of at least one of the
locally stored data, the summarized data, and the remote stream of
sensor data can also or alternatively be sent.
[1429] The methods and systems can include identifying one or more
other accessible signal acquisition instruments (e.g., data
collectors 12008) on an accessible network (e.g., 12010),
nominating at least one of the one or more other accessible signal
acquisition instruments as a logical communication hub, and
providing the logical communication hub with a list of available
data and their associated sources. The list of available data and
their associated sources can be provided to the logical
communication hub utilizing a hybrid peer-to-peer communications
protocol.
[1430] In some aspects, the storage operation can include storing
the data in a local database and automatically organizing at least
one parameter of the data pool utilizing machine learning. The
organizing can be based at least in part on receiving information
regarding at least one of an accuracy of classification and an
accuracy of prediction of an external machine learning system that
uses data from the data pool (e.g., data pool 12014).
[1431] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs and self-organizing at least one of: (i) a storage operation
of the data; (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs.
[1432] The present disclosure describes a system for data
collection in an industrial environment having self-organization
functionality, the system according to one disclosed non-limiting
embodiment of the present disclosure can include a data collector
for handling a plurality of sensor inputs from sensors in the
industrial environment and for generating data associated with the
plurality of sensor inputs, and a self-organizing system for
self-organizing at least one of (i) a storage operation of the
data, (ii) a data collection operation of sensors that provide the
plurality of sensor inputs, and (iii) a selection operation of the
plurality of sensor inputs.
[1433] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs; and self-organizing at least one of: (i) a storage
operation of the data; (ii) a collection operation of sensors that
provide the plurality of sensor inputs, and (iii) a selection
operation of the plurality of sensor inputs, wherein the storage
operation includes storing the data in a local database, and
summarizing the data over a given time period to reduce a size of
the data.
[1434] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes sending the summarized data to one or more data
acquisition boxes.
[1435] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes sending the summarized data to one or more data
centers.
[1436] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein summarizing
the data over a given time period to reduce the size of the data
includes determining a speed at which data can be sent via a
network, wherein the size of the summarized data corresponds to the
speed at which data can be sent continuously in real time via the
network.
[1437] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes continuously sending the summarized data to an
external device via the network.
[1438] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs and self-organizing at least one of: (i) a storage operation
of the data; (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the storage operation
includes storing the data in a local database, summarizing the data
over a given time period to reduce a size of the data, committing
the summarized data to a local ledger, identifying one or more
other accessible signal acquisition instruments on an accessible
network, and synchronizing the summarized data at the local ledger
with at least one of the other accessible signal acquisition
instruments. A further embodiment of any of the foregoing
embodiments of the present disclosure may include situations
wherein the method further includes receiving a remote stream of
sensor data from one or more other accessible signal acquisition
instruments via a network.
[1439] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the method
further includes sending an advertisement message to a potential
client indicating availability of at least one of the locally
stored data, the summarized data, and the remote stream of sensor
data.
[1440] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs;
sampling data received from the sensor inputs, self-organizing at
least one of: (i) a storage operation of the data (ii) a collection
operation of sensors that provide the plurality of sensor inputs,
and (iii) a selection operation of the plurality of sensor inputs,
wherein the storage operation includes storing the data in a local
database, and summarizing the data over a given time period to
reduce a size of the data, identifying one or more other accessible
signal acquisition instruments on an accessible network, nominating
at least one of the one or more other accessible signal acquisition
instruments as a logical communication hub, and providing the
logical communication hub with a list of available data and their
associated sources.
[1441] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the list of
available data and their associated sources is provided to the
logical communication hub utilizing a hybrid peer-to-peer
communications protocol.
[1442] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the storage operation
includes storing the data in a local database, summarizing the data
over a given time period to reduce a size of the data, storing the
data in a local database, and automatically organizing at least one
parameter of the database utilizing machine learning, wherein the
organizing is based at least in part on receiving information
regarding at least one of an accuracy of classification and an
accuracy of prediction of an external machine learning system that
uses data from the database.
[1443] In aspects, the collection operation of sensors that provide
the plurality of sensor inputs can include receiving instructions
directing a mobile data collector unit (e.g., data collector 12008)
to operate sensors at a target (e.g., 12002), wherein at least one
of the plurality of sensors is arranged in the mobile data
collector unit. A communication can be transmitted to one or more
other mobile data collector units (12008) regarding the
instructions. The swarm 12006 or portion thereof can self-organize
a distribution of the mobile data collector unit and the one or
more other mobile data collector units (e.g., data collectors
12008) at the target 12002.
[1444] In aspects, self-organizing the distribution of the mobile
data collector units at the target 12002 comprises utilizing a
machine learning algorithm to determine a respective target
location for each of the mobile data collector units. The machine
learning algorithm can utilize one or more of a plurality of
features to determine the respective target locations. Examples of
the features can include: battery life of the mobile data collector
units (data collectors 12008), a type of the target 12002 being
sensed, a type of signal being sensed, a size of the target 12002,
a number of mobile data collector units (data collectors 12008)
needed to cover the target 12002, a number of data points needed
for the target 12002, a success in prior accomplishment of signal
capture, information received from a headquarters or other
components from which the instructions are received, and historical
information regarding the sensors operated at the target 12002.
[1445] In implementations, self-organizing the distribution of the
mobile data collector unit and the one or more other mobile data
collector units at the target location can include proposing a
target location for the mobile data collector unit(s), transmitting
the target location to at least one other mobile data collector
units, receiving confirmation that there is no contention for the
target location, directing one of the mobile data collector units
to the target location, and collecting sensor data at the target
location from the directed mobile data collector unit.
[1446] Self-organizing the distribution of the mobile data
collector unit and the one or more other mobile data collector
units at the target location can also include, in certain
embodiments, proposing a target location for the mobile data
collector unit, transmitting the target location to at least one of
the one or more other mobile data collector units, receiving a
proposal for a new target location, directing the mobile data
collector unit to the new target location, and collecting sensor
data at the new target location from the mobile data collector
unit.
[1447] In additional or alternative aspects, self-organizing the
distribution of the mobile data collector unit and the one or more
other mobile data collector units at the target location can
comprise proposing a target location for the mobile data collector
unit, determining that at least one of the one or more other mobile
data collector units is at or moving to the target location,
determining a new target location based on the at least one of the
one or more other mobile data collector units being at or moving to
the target location, directing the mobile data collector unit to
the new target location, and collecting sensor data at the new
target location from the mobile data collector unit.
[1448] Self-organizing the distribution of the mobile data
collector unit and the one or more other mobile data collector
units at the target location can further comprise determining a
type of the sensors to operate at the target 12002, receiving
confirmation that there is no contention for the type of sensors,
directing the mobile data collector unit to operate the type of
sensors at the target 12002, and collecting sensor data from the
type of sensors at the target 12002 from the mobile data collector
unit.
[1449] In aspects, self-organizing the distribution of the mobile
data collector unit and the one or more other mobile data collector
units at the target location can include determining a type of the
sensors to operate at the target, transmitting the type of the
sensors to at least one of the one or more other mobile data
collector units, receiving a proposal for a new type of the
sensors, directing the mobile data collector unit to operate the
new type of sensors at the target, and collecting sensor data from
the new type of sensors at the target from the mobile data
collector unit.
[1450] Self-organizing the distribution of the mobile data
collector unit and the one or more other mobile data collector
units at the target location can include determining a type of the
sensors to operate at the target, determining that at least one of
the one or more other mobile data collector units is operating or
can operate the type of the sensors at the target, determining a
new type of the sensors based on the at least one of the one or
more other mobile data collector units operating or being capable
of operating the type of the sensors at the target, directing the
mobile data collector unit to operate the new type of sensors at
the target, and collecting sensor data from the new type of sensors
at the target from the mobile data collector unit.
[1451] Self-organizing the distribution of the mobile data
collector unit and the one or more other mobile data collector
units at the target location, in some implementations, can comprise
utilizing a swarm optimization algorithm to allocate areas of
sensor responsibility amongst the mobile data collector unit and
the one or more other mobile data collector units. Examples of the
swarm optimization algorithm include but are not limited to Genetic
Algorithms (GA), Ant Colony Optimization (ACO), Particle Swarm
Optimization (PSO), Differential Evolution (DE), Artificial Bee
Colony (ABC), Glowworm Swarm Optimization (GSO), and Cuckoo Search
Algorithm (CSA), Genetic Programming (GP), Evolution Strategy (ES),
Evolutionary Programming (EP), Firefly Algorithm (FA), Bat
Algorithm (BA) and Grey Wolf Optimizer (GWO), or combinations
thereof.
[1452] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs.
[1453] The present disclosure describes a system for data
collection in an industrial environment having automated
self-organization, the system according to one disclosed
non-limiting embodiment of the present disclosure can include a
data collector for handling a plurality of sensor inputs from
sensors in the industrial environment and for generating data
associated with the plurality of sensor inputs, and a
self-organizing system for self-organizing at least one of (i) a
storage operation of the data, (ii) a data collection operation of
sensors that provide the plurality of sensor inputs, and (iii) a
selection operation of the plurality of sensor inputs.
[1454] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs;
sampling data received from the sensor inputs and self-organizing
at least one of (i) a storage operation of the data, (ii) a
collection operation of sensors that provide the plurality of
sensor inputs, and (iii) a selection operation of the plurality of
sensor inputs, wherein the collection operation of sensors that
provide the plurality of sensor inputs includes receiving
instructions directing a mobile data collector unit to operate
sensors at a target, wherein at least one of the plurality of
sensors is arranged in the mobile data collector unit, transmitting
a communication to one or more other mobile data collector units
regarding the instructions, and self-organizing a distribution of
the mobile data collector unit and the one or more other mobile
data collector units at the target.
[1455] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
includes utilizing a machine learning algorithm to determine a
respective target location for each of the mobile data collector
units.
[1456] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the machine
learning algorithm utilizes one or more of a plurality of features
to determine the respective target locations, the plurality of
features including: battery life of the mobile data collector
units, a type of the target being sensed, a type of signal being
sensed, a size of the target, a number of mobile data collector
units needed to cover the target, a number of data points needed
for the target, a success in prior accomplishment of signal
capture, information received from a headquarters from which the
instructions are received, and historical information regarding the
sensors operated at the target.
[1457] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes proposing a target location for the mobile data
collector unit, transmitting the target location to at least one of
the one or more other mobile data collector units, receiving
confirmation that there is no contention for the target location,
directing the mobile data collector unit to the target location,
and collecting sensor data at the target location from the mobile
data collector unit.
[1458] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes proposing a target location for the mobile data
collector unit, transmitting the target location to at least one of
the one or more other mobile data collector units, receiving a
proposal for a new target location, directing the mobile data
collector unit to the new target location and collecting sensor
data at the new target location from the mobile data collector
unit.
[1459] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes proposing a target location for the mobile data
collector unit, determining that at least one of the one or more
other mobile data collector units is at or moving to the target
location, determining a new target location based on the at least
one of the one or more other mobile data collector units being at
or moving to the target location, directing the mobile data
collector unit to the new target location and collecting sensor
data at the new target location from the mobile data collector
unit.
[1460] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes determining a type of the sensors to operate at
the target, receiving confirmation that there is no contention for
the type of sensors, directing the mobile data collector unit to
operate the type of sensors at the target, and collecting sensor
data from the type of sensors at the target from the mobile data
collector unit.
[1461] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data (ii) a collection operation of sensors that provide the
plurality of sensor inputs, and (iii) a selection operation of the
plurality of sensor inputs, wherein the collection operation of
sensors that provide the plurality of sensor inputs includes
receiving instructions directing a mobile data collector unit to
operate sensors at a target, wherein at least one of the plurality
of sensors is arranged in the mobile data collector unit,
transmitting a communication to one or more other mobile data
collector units regarding the instructions, self-organizing a
distribution of the mobile data collector unit and the one or more
other mobile data collector units at the target, wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes determining a type of the sensors to operate at
the target, transmitting the type of the sensors to at least one of
the one or more other mobile data collector units, receiving a
proposal for a new type of the sensors, directing the mobile data
collector unit to operate the new type of sensors at the target and
collecting sensor data from the new type of sensors at the target
from the mobile data collector unit.
[1462] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes determining a type of the sensors to operate at
the target, determining that at least one of the one or more other
mobile data collector units is operating or can operate the type of
the sensors at the target, determining a new type of the sensors
based on the at least one of the one or more other mobile data
collector units operating or being capable of operating the type of
the sensors at the target, directing the mobile data collector unit
to operate the new type of sensors at the target, and collecting
sensor data from the new type of sensors at the target from the
mobile data collector unit.
[1463] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein
self-organizing the distribution of the mobile data collector unit
and the one or more other mobile data collector units at the target
location includes utilizing a swarm optimization algorithm to
allocate areas of sensor responsibility amongst the mobile data
collector unit and the one or more other mobile data collector
units.
[1464] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the swarm
optimization algorithm is one or more types of Genetic Algorithms
(GA), Ant Colony Optimization (ACO), Particle Swarm Optimization
(PSO), Differential Evolution (DE), Artificial Bee Colony (ABC),
Glowworm Swarm Optimization (GSO), and Cuckoo Search Algorithm
(CSA), Genetic Programming (GP), Evolution Strategy (ES),
Evolutionary Programming (EP), Firefly Algorithm (FA), Bat
Algorithm (BA) and Grey Wolf Optimizer (GWO).
[1465] In aspects, the selection operation can comprise receiving a
signal relating to at least one condition of the industrial
environment 12000 and, based on the signal, changing at least one
of the sensor inputs analyzed and a frequency of the sampling. The
at least one condition of the industrial environment can be a
signal-to-noise ratio of the sampled data. The selection operation
can include identifying a target signal to be sensed. Additionally,
the selection operation further can include identifying one or more
non-target signals in a same frequency band as the target signal to
be sensed and, based on the identified one or more non-target
signals, changing at least one of the sensor inputs analyzed and a
frequency of the sampling.
[1466] The selection operation can comprise identifying other data
collectors sensing in a same signal band as the target signal to be
sensed, and, based on the identified other data collectors,
changing at least one of the sensor inputs analyzed and a frequency
of the sampling. In implementations, the selection operation can
further comprise identifying a level of activity of a target
associated with the target signal to be sensed and, based on the
identified level of activity, changing at least one of the sensor
inputs analyzed and a frequency of the sampling.
[1467] The selection operation can further comprise receiving data
indicative of environmental conditions near a target associated
with the target signal, comparing the received environmental
conditions of the target with past environmental conditions near
the target or another target similar to the target, and, based on
the comparison, changing at least one of the sensor inputs analyzed
and a frequency of the sampling. At least a portion of the received
sampling data can be transmitted to another data collector
according to a predetermined hierarchy of data collection.
[1468] The selection operation further comprises, in some aspects,
receiving data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to a quality or sufficiency of
the transmitted data, analyzing the received feedback, and, based
on the analysis of the received feedback, changing at least one of
the sensor inputs analyzed, the frequency of sampling, the data
stored, and the data transmitted.
[1469] Additionally, or alternatively, the selection operation can
comprise receiving data indicative of environmental conditions near
a target associated with the target signal, transmitting at least a
portion of the received sampling data to another data collector
according to a predetermined hierarchy of data collection,
receiving feedback via a network connection relating to one or more
yield metrics of the transmitted data, analyzing the received
feedback, and, based on the analysis of the received feedback,
changing at least one of the sensor inputs analyzed, the frequency
of sampling, the data stored, and the data transmitted.
[1470] In implementations, the selection operation can include
receiving data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to power utilization, analyzing
the received feedback, and based on the analysis of the received
feedback, changing at least one of the sensor inputs analyzed, the
frequency of sampling, the data stored, and the data
transmitted.
[1471] The selection operation can also or alternatively comprise
receiving data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to a quality or sufficiency of
the transmitted data, analyzing the received feedback, and, based
on the analysis of the received feedback, executing a
dimensionality reduction algorithm on the sensed data. The
dimensionality reduction algorithm can be one or more of a Decision
Tree, Random Forest, Principal Component Analysis, Factor Analysis,
Linear Discriminant Analysis, Identification based on correlation
matrix, Missing Values Ratio, Low Variance Filter, Random
Projections, Nonnegative Matrix Factorization, Stacked
Auto-encoders, Chi-square or Information Gain, Multidimensional
Scaling, Correspondence Analysis, Factor Analysis, Clustering, and
Bayesian Models. The dimensionality reduction algorithm can be
performed at a data collector 12008, a swarm 12006 of data
collectors 12008, a network 12010, a computing system 12012, a data
pool 12014, or combination thereof. In aspects, executing the
dimensionality reduction algorithm can comprise sending the sensed
data to a remote computing device.
[1472] In aspects, a system for self-organizing collection and
storage of data collection in a power generation environment can
include a data collector for handling a plurality of sensor inputs
from various sensors. Such sensors can be a component of the data
collector, external to the data collector (e.g., external sensors
or components of different data collector(s)), or a combination
thereof. The plurality of sensor inputs can be configured to sense
at least one of an operational mode, a fault mode, and a health
status of at least one target system. Examples of such target
systems include but are not limited to a fuel handling system, a
power source, a turbine, a generator, a gear system, an electrical
transmission system, a transformer, a fuel cell, and an energy
storage device/system. The system can also include a
self-organizing system that can be configured for self-organizing
at least one of: (i) a storage operation of the data; (ii) a data
collection operation of the sensors that provide the plurality of
sensor inputs, and (iii) a selection operation of the plurality of
sensor input, as is described herein.
[1473] In aspects, the system can include a swarm 12006 of mobile
data collectors (e.g., data collectors 12008). Further, in
additional or alternative aspects, the self-organizing system can
generate, iterate, optimize, etc. a storage specification for
organizing storage of the data. The storage specification, e.g.,
can specify which data will be stored for local storage in the
power generation environment, and which data will be output for
streaming via a network connection (e.g., network 12010) from the
power generation environment. Other data collection, generation,
and/or storage operations can be performed or enabled by the
system, as is described herein.
[1474] In a non-limiting example, the system can include a
plurality of sensors configured to sense various parameters in the
environment of a turbine as a target system. Vibration sensors,
temperature sensors, acoustic sensors, strain gauges, and
accelerometers, and the like may be utilized by the system to
generate data regarding the operation of the turbine. As mentioned
herein, any and all of the storage operation, the data collection
operation, and the selection operation of the plurality of sensor
inputs may be adapted, optimized, learned, or otherwise
self-organized by the system.
[1475] In aspects, a system for self-organizing collection and
storage of data collection in energy source extraction environment
can include a data collector for handling a plurality of sensor
inputs from various sensors. Examples of such energy source
extraction environments include a coal mining environment, a metal
mining environment, a mineral mining environment, and an oil
drilling environment, although other extraction environments are
contemplated by the present disclosure. The sensors utilized can be
a component of the data collector, external to the data collector
(e.g., external sensors or components of different data
collector(s)), or a combination thereof. The plurality of sensor
inputs can be configured to sense at least one of an operational
mode, a fault mode, and a health status of at least one target
system. Examples of such target systems include but are not limited
to a hauling system, a lifting system, a drilling system, a mining
system, a digging system, a boring system, a material handling
system, a conveyor system, a pipeline system, a wastewater
treatment system, and a fluid pumping system.
[1476] The system can also include a self-organizing system that
can be configured for self-organizing at least one of: (i) a
storage operation of the data; (ii) a data collection operation of
the sensors that provide the plurality of sensor inputs, and (iii)
a selection operation of the plurality of sensor input, as is
described herein. In aspects, the system can include a swarm 12006
of mobile data collectors (e.g., data collectors 12008). Further,
in additional or alternative aspects, the self-organizing system
can generate, iterate, optimize, etc. a storage specification for
organizing storage of the data. The storage specification, e.g.,
can specify which data will be stored for local storage in the
power generation environment, and which data will be output for
streaming via a network connection (e.g., network 12010) from the
power generation environment. Other data collection, generation,
and/or storage operations can be performed or enabled by the
system, as is described herein.
[1477] In a non-limiting example, the system can include a
plurality of sensors configured to sense various parameters in the
environment of a fluid pumping system as a target system. Vibration
sensors, flow sensors, pressure sensors, temperature sensors,
acoustic sensors, and the like may be utilized by the system to
generate data regarding the operation of the fluid pumping system.
As mentioned herein, any and all of the storage operation, the data
collection operation, and the selection operation of the plurality
of sensor inputs may be adapted, optimized, learned, or otherwise
self-organized by the system.
[1478] In implementations, a system for self-organizing collection
and storage of data collection in a manufacturing environment can
include a data collector for handling a plurality of sensor inputs
from various sensors. Such sensors can be a component of the data
collector, external to the data collector (e.g., external sensors
or components of different data collector(s)), or a combination
thereof. The plurality of sensor inputs can be configured to sense
at least one of an operational mode, a fault mode, and a health
status of at least one target system. Examples of such target
systems include but are not limited to a power system, a conveyor
system, a generator, an assembly line system, a wafer handling
system, a chemical vapor deposition system, an etching system, a
printing system, a robotic handling system, a component assembly
system, an inspection system, a robotic assembly system, and a
semi-conductor production system. The system can also include a
self-organizing system that can be configured for self-organizing
at least one of: (i) a storage operation of the data; (ii) a data
collection operation of the sensors that provide the plurality of
sensor inputs, and (iii) a selection operation of the plurality of
sensor input, as is described herein.
[1479] In aspects, the system can include a swarm 12006 of mobile
data collectors (e.g., data collectors 12008). Further, in
additional or alternative aspects, the self-organizing system can
generate, iterate, optimize, etc. a storage specification for
organizing storage of the data. The storage specification, e.g.,
can specify which data will be stored for local storage in the
power generation environment, and which data will be output for
streaming via a network connection (e.g., network 12010) from the
power generation environment. Other data collection, generation,
and/or storage operations can be performed or enabled by the
system, as is described herein.
[1480] In a non-limiting example, the system can include a
plurality of sensors configured to sense various parameters in the
environment of a wafer handling system as a target system.
Vibration sensors, fluid flow sensors, pressure sensors, gas
sensors, temperature sensors, and the like may be utilized by the
system to generate data regarding the operation of the wafer
handling system. As mentioned herein, any and all of the storage
operation, the data collection operation, and the selection
operation of the plurality of sensor inputs may be adapted,
optimized, learned, or otherwise self-organized by the system.
[1481] Also disclosed are embodiments of an additional or
alternative system for self-organizing collection and storage of
data collection in refining environment. Such system(s) can include
a data collector for handling a plurality of sensor inputs from
various sensors. Examples of such refining environments include a
chemical refining environment, a pharmaceutical refining
environment, a biological refining environment, and a hydrocarbon
refining environment, although other refining environments are
contemplated by the present disclosure. The sensors utilized can be
a component of the data collector, external to the data collector
(e.g., external sensors or components of different data
collector(s)), or a combination thereof. The plurality of sensor
inputs can be configured to sense at least one of an operational
mode, a fault mode, and a health status of at least one target
system. Examples of such target systems include but are not limited
to a power system, a pumping system, a mixing system, a reaction
system, a distillation system, a fluid handling system, a heating
system, a cooling system, an evaporation system, a catalytic
system, a moving system, and a container system.
[1482] The system can also include a self-organizing system that
can be configured for self-organizing at least one of: (i) a
storage operation of the data; (ii) a data collection operation of
the sensors that provide the plurality of sensor inputs, and (iii)
a selection operation of the plurality of sensor input, as is
described herein. In aspects, the system can include a swarm 12006
of mobile data collectors (e.g., data collectors 12008). Further,
in additional or alternative aspects, the self-organizing system
can generate, iterate, optimize, etc. a storage specification for
organizing storage of the data. The storage specification, e.g.,
can specify which data will be stored for local storage in the
power generation environment, and which data will be output for
streaming via a network connection (e.g., network 12010) from the
power generation environment. Other data collection, generation,
and/or storage operations can be performed or enabled by the
system, as is described herein.
[1483] In a non-limiting example, the system can include a
plurality of sensors configured to sense various parameters in the
refining environment of a heating system as a target system.
Temperature sensors, fluid flow sensors, pressure sensors, and the
like may be utilized by the system to generate data regarding the
operation of the heating system. As mentioned herein, any and all
of the storage operation, the data collection operation, and the
selection operation of the plurality of sensor inputs may be
adapted, optimized, learned, or otherwise self-organized by the
system.
[1484] In aspects, a system for self-organizing collection and
storage of data collection in a distribution environment can
include a data collector for handling a plurality of sensor inputs
from various sensors. Such sensors can be a component of the data
collector, external to the data collector (e.g., external sensors
or components of different data collector(s)), or a combination
thereof. The plurality of sensor inputs can be configured to sense
at least one of an operational mode, a fault mode, and a health
status of at least one target system. Examples of such target
systems include but are not limited to a power system, a conveyor
system, a robotic transport system, a robotic handling system, a
packing system, a cold storage system, a hot storage system, a
refrigeration system, a vacuum system, a hauling system, a lifting
system, an inspection system, and a suspension system. The system
can also include a self-organizing system that can be configured
for self-organizing at least one of: (i) a storage operation of the
data; (ii) a data collection operation of the sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor input, as is described herein.
[1485] In aspects, the system can include a swarm 12006 of mobile
data collectors (e.g., data collectors 12008). Further, in
additional or alternative aspects, the self-organizing system can
generate, iterate, optimize, etc. a storage specification for
organizing storage of the data. The storage specification, e.g.,
can specify which data will be stored for local storage in the
power generation environment, and which data will be output for
streaming via a network connection (e.g., network 12010) from the
power generation environment. Other data collection, generation,
and/or storage operations can be performed or enabled by the
system, as is described herein.
[1486] In a non-limiting example, the system can include a
plurality of sensors configured to sense various parameters in the
distribution environment of a refrigeration system as a target
system. Power sensors, temperature sensors, vibration sensors,
strain gauges, and the like may be utilized by the system to
generate data regarding the operation of the turbine. As mentioned
herein, any and all of the storage operation, the data collection
operation, and the selection operation of the plurality of sensor
inputs may be adapted, optimized, learned, or otherwise
self-organized by the system.
[1487] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs.
[1488] The present disclosure describes a system for data
collection in an industrial environment having automated
self-organization, the system according to one disclosed
non-limiting embodiment of the present disclosure can include a
data collector for handling a plurality of sensor inputs from
sensors in the industrial environment and for generating data
associated with the plurality of sensor inputs, and a
self-organizing system for self-organizing at least one of (i) a
storage operation of the data, (ii) a data collection operation of
sensors that provide the plurality of sensor inputs, and (iii) a
selection operation of the plurality of sensor inputs.
[1489] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the selection operation
includes receiving a signal relating to at least one condition of
the industrial environment, based on the signal, changing at least
one of the sensor inputs analyzed and a frequency of the
sampling.
[1490] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the at least
one condition of the industrial environment is a signal-to-noise
ratio of the sampled data.
[1491] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the selection
operation includes identifying a target signal to be sensed.
[1492] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the selection
operation further includes identifying one or more non-target
signals in a same frequency band as the target signal to be sensed,
and based on the identified one or more non-target signals,
changing at least one of the sensor inputs analyzed and a frequency
of the sampling.
[1493] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the selection
operation further includes identifying other data collectors
sensing in a same signal band as the target signal to be sensed,
and based on the identified other data collectors, changing at
least one of the sensor inputs analyzed and a frequency of the
sampling.
[1494] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the selection
operation further includes identifying a level of activity of a
target associated with the target signal to be sensed, and based on
the identified level of activity, changing at least one of the
sensor inputs analyzed and a frequency of the sampling.
[1495] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the selection
operation further includes receiving data indicative of
environmental conditions near a target associated with the target
signal, comparing the received environmental conditions of the
target with past environmental conditions near the target or
another target similar to the target, and based on the comparison,
changing at least one of the sensor inputs analyzed and a frequency
of the sampling.
[1496] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the selection
operation further includes transmitting at least a portion of the
received sampling data to another data collector according to a
predetermined hierarchy of data collection.
[1497] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the selection operation
includes identifying a target signal to be sensed, receiving a
signal relating to at least one condition of the industrial
environment, based on the signal, changing at least one of the
sensor inputs analyzed and a frequency of the sampling, receiving
data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to a quality or sufficiency of
the transmitted data, analyzing the received feedback, and based on
the analysis of the received feedback, changing at least one of the
sensor inputs analyzed, the frequency of sampling, the data stored,
and the data transmitted.
[1498] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the selection operation
includes identifying a target signal to be sensed, receiving a
signal relating to at least one condition of the industrial
environment, based on the signal, changing at least one of the
sensor inputs analyzed and a frequency of the sampling, receiving
data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to one or more yield metrics of
the transmitted data, analyzing the received feedback, and based on
the analysis of the received feedback, changing at least one of the
sensor inputs analyzed, the frequency of sampling, the data stored,
and the data transmitted.
[1499] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the selection operation
includes identifying a target signal to be sensed, receiving a
signal relating to at least one condition of the industrial
environment, based on the signal, changing at least one of the
sensor inputs analyzed and a frequency of the sampling, receiving
data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving
feedback, via a network connection relating to power utilization,
analyzing the received feedback, and based on the analysis of the
received feedback, changing at least one of the sensor inputs
analyzed, the frequency of sampling, the data stored, and the data
transmitted.
[1500] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the selection operation
includes identifying a target signal to be sensed, receiving a
signal relating to at least one condition of the industrial
environment, based on the signal, changing at least one of the
sensor inputs analyzed and a frequency of the sampling, receiving
data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to a quality or sufficiency of
the transmitted data, analyzing the received feedback, and based on
the analysis of the received feedback, executing a dimensionality
reduction algorithm on the sensed data.
[1501] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
dimensionality reduction algorithm is one or more of a Decision
Tree, Random Forest, Principal Component Analysis, Factor Analysis,
Linear Discriminant Analysis, Identification based on correlation
matrix, Missing Values Ratio, Low Variance Filter, Random
Projections, Nonnegative Matrix Factorization, Stacked
Auto-encoders, Chi-square or Information Gain, Multidimensional
Scaling, Correspondence Analysis, Factor Analysis, Clustering, and
Bayesian Models.
[1502] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
dimensionality reduction algorithm is performed at a data
collector.
[1503] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein executing the
dimensionality reduction algorithm includes sending the sensed data
to a remote computing device.
[1504] The present disclosure describes a method for data
collection in an industrial environment having self-organization
functionality, the method according to one disclosed non-limiting
embodiment of the present disclosure can include analyzing a
plurality of sensor inputs, sampling data received from the sensor
inputs, and self-organizing at least one of (i) a storage operation
of the data, (ii) a collection operation of sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs, wherein the selection operation
includes identifying a target signal to be sensed, receiving a
signal relating to at least one condition of the industrial
environment, based on the signal, changing at least one of the
sensor inputs analyzed and a frequency of the sampling, receiving
data indicative of environmental conditions near a target
associated with the target signal, transmitting at least a portion
of the received sampling data to another data collector according
to a predetermined hierarchy of data collection, receiving feedback
via a network connection relating to at least one of a bandwidth
and a quality or of the network connection, analyzing the received
feedback, and based on the analysis of the received feedback,
changing at least one of the sensor inputs analyzed, the frequency
of sampling, the data stored, and the data transmitted.
[1505] The present disclosure describes a system for
self-organizing collection and storage of data collection in a
power generation environment, the system according to one disclosed
non-limiting embodiment of the present disclosure can include a
data collector for handling a plurality of sensor inputs from
sensors in the power generation environment, wherein the plurality
of sensor inputs is configured to sense at least one of an
operational mode, a fault mode, and a health status of at least one
target system selected from a group consisting of a fuel handling
system, a power source, a turbine, a generator, a gear system, an
electrical transmission system, and a transformer, and a
self-organizing system for self-organizing at least one of (i) a
storage operation of the data, (ii) a data collection operation of
the sensors that provide the plurality of sensor inputs, and (iii)
a selection operation of the plurality of sensor inputs.
[1506] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system organizes a swarm of mobile data collectors
to collect data from a plurality of target systems.
[1507] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system generates a storage specification for
organizing storage of the data, the storage specification
specifying data for local storage in the power generation
environment and specifying data for streaming via a network
connection from the power generation environment.
[1508] The present disclosure describes a system for
self-organizing collection and storage of data collection in an
energy source extraction environment, the system according to one
disclosed non-limiting embodiment of the present disclosure can
include a data collector for handling a plurality of sensor inputs
from sensors in the energy extraction environment, wherein the
plurality of sensor inputs is configured to sense at least one of
an operational mode, a fault mode, and a health status of at least
one target system selected from a group consisting of a hauling
system, a lifting system, a drilling system, a mining system, a
digging system, a boring system, a material handling system, a
conveyor system, a pipeline system, a wastewater treatment system,
and a fluid pumping system, and a self-organizing system for
self-organizing at least one of (i) a storage operation of the
data, (ii) a data collection operation of the sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs.
[1509] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system organizes a swarm of mobile data collectors
to collect data from a plurality of target systems.
[1510] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system generates a storage specification for
organizing storage of the data, the storage specification
specifying data for local storage in the energy extraction
environment and specifying data for streaming via a network
connection from the energy extraction environment.
[1511] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the energy
source extraction environment is a coal mining environment.
[1512] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the energy
source extraction environment is a metal mining environment.
[1513] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the energy
source extraction environment is a mineral mining environment.
[1514] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the energy
source extraction environment is an oil drilling environment.
[1515] The present disclosure describes a system for
self-organizing collection and storage of data collection in a
manufacturing environment, the system according to one disclosed
non-limiting embodiment of the present disclosure can include a
data collector for handling a plurality of sensor inputs from
sensors in the power generation environment, wherein the plurality
of sensor inputs is configured to sense at least one of an
operational mode, a fault mode, and a health status of at least one
target system selected from a group consisting of a power system, a
conveyor system, a generator, an assembly line system, a wafer
handling system, a chemical vapor deposition system, an etching
system, a printing system, a robotic handling system, a component
assembly system, an inspection system, a robotic assembly system,
and a semi-conductor production system, and a self-organizing
system for self-organizing at least one of (i) a storage operation
of the data, (ii) a data collection operation of the sensors that
provide the plurality of sensor inputs, and (iii) a selection
operation of the plurality of sensor inputs.
[1516] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system organizes a swarm of mobile data collectors
to collect data from a plurality of target systems.
[1517] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system generates a storage specification for
organizing the storage of the data, the storage specification
specifying data for local storage in the manufacturing environment
and specifying data for streaming via a network connection from the
manufacturing environment.
[1518] The present disclosure describes a system for
self-organizing collection and storage of data collection in a
refining environment, the system according to one disclosed
non-limiting embodiment of the present disclosure can include a
data collector for handling a plurality of sensor inputs from
sensors in the power generation environment, wherein the plurality
of sensor inputs is configured to sense at least one of an
operational mode, a fault mode and a health status of at least one
target system selected from a group consisting of a power system, a
pumping system, a mixing system, a reaction system, a distillation
system, a fluid handling system, a heating system, a cooling
system, an evaporation system, a catalytic system, a moving system,
and a container system, and a self-organizing system for
self-organizing at least one of (i) a storage operation of the
data, (ii) a data collection operation of the sensors that provide
the plurality of sensor inputs, and (iii) a selection operation of
the plurality of sensor inputs.
[1519] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system organizes a swarm of mobile data collectors
to collect data from a plurality of target systems.
[1520] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system generates a storage specification for
organizing the storage of the data, the storage specification
specifying data for local storage in the refining environment and
specifying data for streaming via a network connection from the
refining environment.
[1521] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the refining
environment is a chemical refining environment.
[1522] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the refining
environment is a pharmaceutical refining environment.
[1523] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the refining
environment is a biological refining environment.
[1524] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the refining
environment is a hydrocarbon refining environment.
[1525] The present disclosure describes a system for
self-organizing collection and storage of data collection in a
distribution environment, the system according to one disclosed
non-limiting embodiment of the present disclosure can include a
data collector for handling a plurality of sensor inputs from
sensors in the distribution environment, wherein the plurality of
sensor inputs is configured to sense at least one of an operational
mode, a fault mode and a health status of at least one target
system selected from a group consisting of a power system, a
conveyor system, a robotic transport system, a robotic handling
system, a packing system, a cold storage system, a hot storage
system, a refrigeration system, a vacuum system, a hauling system,
a lifting system, an inspection system, and a suspension system,
and a self-organizing system for self-organizing at least one of
(i) a storage operation of the data, (ii) a data collection
operation of the sensors that provide the plurality of sensor
inputs, and (iii) a selection operation of the plurality of sensor
inputs.
[1526] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system organizes a swarm of mobile data collectors
to collect data from a plurality of target systems.
[1527] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
self-organizing system generates a storage specification for
organizing the storage of the data, the storage specification
specifying data for local storage in the distribution environment
and specifying data for streaming via a network connection from the
distribution environment.
[1528] Referencing FIG. 165, an example system 12200 for
self-organized, network-sensitive data collection in an industrial
environment is depicted. The system 12200 includes an industrial
system 12202 having a number of components 12204, and a number of
sensors 12206, wherein each of the sensors 12206 is operatively
coupled to at least one of the components 12204. The selection,
distribution, type, and communicative setup of sensors depends upon
the application of the system 12200 and/or the context.
[1529] In certain embodiments, sensor data values 12204 are
provided to a data collector 12208, which may be in communication
with multiple sensors 12206 and/or with a controller 12212. In
certain embodiments, a plant computer 12210 is additionally or
alternatively present. In the example system, the controller 12212
is structured to functionally execute operations of the sensor
communication circuit 12224, sensor data storage profile circuit
12226, sensor data storage implementation circuit 12228, storage
planning circuit 12230, and/or haptic feedback circuit 12232. The
controller 12212 is depicted as a separate device for clarity of
description. Aspects of the controller 12212 may be present on the
sensors 12206, the data controller 12208, the plant computer 12210,
and/or on a cloud computing device 12214. In certain embodiments
described throughout this disclosure, all aspects of the controller
12212 or other controllers may be present in another device
depicted on the system 12200. The plant computer 12210 represents
local computing resources, for example processing, memory, and/or
network resources, that may be present and/or in communication with
the industrial system 12200. In certain embodiments, the cloud
computing device 12214 represents computing resources externally
available to the industrial system 12202, for example over a
private network, intra-net, through cellular communications,
satellite communications, and/or over the internet. In certain
embodiments, the data controller 12208 may be a computing device, a
smart sensor, a MUX box, or other data collection device capable to
receive data from multiple sensors and to pass-through the data
and/or store data for later transmission. An example data
controller 12208 has no storage and/or limited storage, and
selectively passes sensor data therethrough, with a subset of the
sensor data being communicated at a given time due to bandwidth
considerations of the data controller 12208, a related network,
and/or imposed by environmental constraints. In certain
embodiments, one or more sensors and/or computing devices in the
system 12200 are portable devices such as the user associated
device 12216 associated with a user 12218, for example a plant
operator walking through the industrial system may have a smart
phone, which the system 12200 may selectively utilize as a data
controller 12208, sensor 12206--for example to enhance
communication throughput, sensor resolution, and/or as a primary
method for communicating sensor data values 12244 to the controller
12212. The system 12200 depicts the controller 12212, the sensors
12206, the data controller 12208, the plant computer 12210, and/or
the cloud computing device 12214 having a memory storage for
storing sensor data thereon, any one or more of which may not have
a memory storage for storing sensor data thereon.
[1530] The example system 12200 further includes a mesh network
12220 having a plurality of network nodes depicted thereupon. The
mesh network 12220 is depicted in a single location for convenience
of illustration, but it will be understood that any network
infrastructure that is within the system 12200, and/or within
communication with the system 12200, including intermittently, is
contemplated within the system network. Additionally, any or all of
the cloud server 12214, plant computer 12210, controller 12212,
data controller 12208, any network capable sensor 12206, and/or
user associated device 12218 may be a part of the network for the
system, including a mesh network 12220, during at least certain
operating conditions of the system 12200. Additionally, or
alternatively, the system 12200 may utilize a hierarchical network,
a peer-to-peer network, a peer-to-peer network with one or more
super-nodes, combinations of these, hybrids of these, and/or may
include multiple networks within the system 12200 or in
communication with the system. It will be appreciated that certain
features and operations of the present disclosure are beneficial to
only one or more than one of these types of networks, certain
features and operations of the present disclosure are beneficial to
any type of network, and certain features and operations are
particularly beneficial to combinations of these networks, and/or
to networks having multiple networking options within the network,
where the benefits relate to the utilization of options of any
type, or where the benefits relate to one or more options being of
a specific network type.
[1531] Referencing FIG. 166, an example apparatus 12222 includes
the controller 12212 having a sensor communication circuit 12224
that interprets a number of sensor data values 12244 from the
number of sensors 12206 and a system collaboration circuit 12228
that communicates at least a portion of the number of sensor data
values (e.g., sensor data 12244 to target storage 12252) to a
storage target computing device according to a sensor data
transmission protocol 12232. The target computing device includes
any device in the system having memory that is the target location
for the selected sensor data 12252. For example, the cloud server
12214, plant computer 12210, the user associated device 12218,
and/or another portion of the controller 12212 that communicates
with the sensor 12206 and/or data controller 12208 over the network
of the system. The target computing device may be a short-term
target (e.g., until a process operation is completed), a
medium-term target (e.g., to be held until certain processing
operations are completed on the data, and/or until a periodic data
migration occurs), and/or a long-term target (e.g., to be held for
the course of a data retention policy, and/or until a long-term
data migration is planned), and/or the data storage target for an
unknown period (e.g., data is passed to a cloud server 12214,
whereupon the system 12200, in certain embodiments, does not
maintain control of the data). In certain embodiments, the target
computing device is the next computing device in the system planned
to store the data. In certain embodiments, the target computing
device is the next computing device in the system where the data
will be moved, where such a move occurs across any aspect of the
network of the system 12200.
[1532] The example controller 12212 includes a transmission
environment circuit 12226 that determines transmission conditions
12254 corresponding to the communication of the at least a portion
of the number of sensor data values 12252 to the storage target
computing device. Transmission conditions 12254 include any
conditions affecting the transmission of the data. For example,
referencing FIG. 169, example and non-limiting transmission
conditions 12254 are depicted including environmental conditions
12272 (e.g., EM noise, vibration, temperature, the presence and
layout of devices or components affecting transmission, such as
metal, conductive, or high density) including environmental
conditions 12272 that affect communications directly, and
environmental conditions 12272 that affect network devices such as
routers, servers, transmitters/transceivers, and the like. An
example transmission conditions 12254 includes a network
performance 12274, such as the specifications of network equipment
or nodes, specified limitations of network equipment or nodes
(e.g., utilization limits, authorization for usage, available
power, etc.), estimated limitations of the network (e.g., based on
equipment temperatures, noise environment, etc.), and/or actual
performance of the network (e.g., as observed directly such as by
timing messages, sending diagnostic messages, or determining
throughput, and/or indirectly by observing parameters such as
memory buffers, arriving messages, etc. that tend to provide
information about the performance of the network). Another example
transmission condition 12254 includes network parameters 12276,
such as timing parameters 12278 (e.g., clock speeds, message
speeds, synchronous speeds, asynchronous speeds, and the like),
protocol selections 12280 (e.g., addressing information, message
sizes including administrative support bits within messages, and/or
speeds supported by the protocols present or available), file type
selections 12282 (e.g., data transfer file types, stored file
types, and the network implications such as how much data must be
transferred before data is at least partially readable, how to
determine data is transferred, likely or supported file sizes, and
the like), streaming parameter selections 12284 (e.g., streaming
protocols, streaming speeds, priority information of streaming
data, available nodes and/or computing devices to manage the
streaming data, and the like), and/or compression parameters 12286
(e.g., compression algorithm and type, processing implications at
each end of the message, lossy versus lossless compression, how
much information must be passed prior to usable data being
available, and the like).
[1533] Referencing FIG. 170, certain further non-limiting examples
of transmission conditions 12254 corresponding to the communication
of the sensor data 12252 are depicted. Example and non-limiting
transmission conditions 12254 include a mesh network need 12288
(e.g., to rearrange the mesh to balance throughput), a parent node
connectivity change 12290 in a hierarchically arranged network
(e.g., the parent node has lost connectivity, re-gained
connectivity, and/or has changed to a different set of child nodes
and/or higher nodes), and/or a network super-node in a hybrid
peer-to-peer application-layer network has been replaced 12292. A
super-node, as utilized herein, is a node having additional
capability from other peer-to-peer nodes. Such additional
capability may be by design only--for example a super-node may
connect in a different manner and/or to nodes outside of the
peer-to-peer node system. In certain embodiments, the super-node
may additionally or alternatively have more processing power,
increased network speed or throughput access, and/or more memory
(e.g., for buffering, caching, and/or short term storage) to
provide more capability to meet the functions of the
super-node.
[1534] An example transmission condition 12254 includes a node in a
mesh or hierarchical network detected as malicious (e.g., from
another supervisory process, heuristically, or as indicated to the
system 12200); a peer node has experienced a bandwidth or
connectivity change 12296 (e.g., mesh network peer that was
forwarding packets has lost connectivity, gained additional
bandwidth, had a reduction in available bandwidth, and/or has
regained connectivity). An example transmission condition 12254
includes a change in a cost of transmitting information 12298
(e.g., cost has increased or decreased, where cost may be a direct
cost parameter such as a data transmission subscription cost, or an
abstracted cost parameter reflecting overall system priorities,
and/or a current cost of delivering information over a network hop
has changed), a change has been made in a hierarchical network
arrangement (e.g., network arrangement change 12300) such as to
balance bandwidth use in a network tree; and/or a change in a
permission scheme 12302 (e.g., a portion of the network relaying
sampling data has had a change in permissions, authorization level,
or credentials). Certain further example transmission conditions
12254 include the availability of an additional connection type
12304 (e.g., a higher-bandwidth network connection type has become
available, and/or a lower-cost network connection type has become
available); a change has been made in a network topology 12306
(e.g., a node has gone offline or online, a mesh change has
occurred, and/or a hierarchy change has occurred); and/or a data
collection client changed a preference or a requirement 12308
(e.g., a data frequency requirement for at least one of the number
of sensor values; a data type requirement for at least one of the
number of sensor values; a sensor target for data collection;
and/or a data collection client has changed the storage target
computing device, which may change the network delivery outcomes
and routing).
[1535] The example controller 12212 includes a network management
circuit 12230 that updates the sensor data transmission protocol
12232 in response to the transmission conditions 12254. For
example, where the transmission conditions 12254 indicate that a
current routing, protocol, delivery frequency, delivery rate,
and/or any other parameter associated with communicating the sensor
data 12252 is no longer cost effective, possible, optimal, and/or
where an improvement is available, the network management circuit
12230 updates the sensor data transmission protocol 12232 in
response to a lower cost, possible, optimal, and/or improved
transmission condition. The example system collaboration circuit
12228 is further responsive to the updated sensor data transmission
protocol 12232--for example, implementing subsequent communications
of the sensor data 12252 in compliance with the updated sensor data
transmission protocol 12232, providing a communication to the
network management circuit 12230 indicating which aspects of the
updated sensor data transmission protocol 12232 cannot be or are
not being followed, and/or providing an alert (e.g., to an
operator, a network node, controller 12212, and/or the network
management circuit 12230) indicating that a change is requested,
indicating that a change is being implemented, and/or indicating
that a requested change cannot be or is not being implemented.
[1536] An example system 12200 includes the transmission conditions
12254 being environmental conditions 12272 relating to sensor
communication of the number of sensor data values 12252, where the
network management circuit 12230 further analyzes the environmental
conditions 12272, and where updating the sensor data transmission
protocol 12232 includes modifying the manner in which the number of
sensor data values are transmitted from the number of sensors 12206
to the storage target computing device. An example system further
includes a data collector 12208 communicatively coupled to at least
a portion of the number of sensors 12206 and responsive to the
sensor data transmission protocol 12232, where the system
collaboration circuit 12228 further receives the number of sensor
data values 12244 from the at least a portion of the number of
sensors, and where the transmission conditions 12254 correspond to
at least one network parameter corresponding to the communication
of the number of sensor data values from the at least a portion of
the number of sensors. Referencing FIG. 171, a number of example
sensor data transmission protocol 12232 values are depicted. An
example sensor data transmission protocol 12232 value includes a
data collection rate 12310--for example a rate and/or a frequency
at which a sensor 12206 transmits, provides, or samples data,
and/or at which the data collector 12208 receives, passes along,
stores, or otherwise captures sensor data. An example network
management circuit 12230 further updates the sensor data
transmission protocol 12232 to modify the data collector 12208 to
adjust a data collection rate 12310 for at least one of the number
of sensors. Another example sensor data transmission protocol 12232
value includes a multiplexing schedule 12312, which includes a data
collector 12208 and/or a smart sensor configured to provide
multiple sensor data values, such as in an alternating or other
scheduled manner, and/or to package multiple sensor values into a
single message in a configured manner. An example network
management circuit 12230 updates the sensor data transmission
protocol 12232 to modify a multiplexing schedule of the data
collector 12208 and/or smart sensor. Another example sensor data
transmission protocol 12232 value includes an intermediate storage
operation 12314, where an intermediate storage is a storage at any
location in the system at least one network transmission prior to
the target storage computing device. Intermediate storage may be
implemented as an on-demand operation, where a request of the data
(e.g., from a user, a machine learning operation, or another system
component) results in the subsequent transfer from the intermediate
storage to the target computing device, and/or the intermediate
storage may be implemented to time shift network communications to
lower cost and/or lower network utilization times, and/or to manage
moment-to-moment traffic on the network. The example network
management circuit 12230 updates the sensor data transmission
protocol 12232 to command an intermediate storage operation for at
least a portion of the number of sensor data values, where the
intermediate storage may be on a sensor, data collector, a node in
the mesh network, on the controller, on a component, and/or in any
other location within the system. An example sensor data
transmission protocol 12232 includes a command for further data
collection 12316 for at least a portion of the number of
sensors--for example because a resolution, rate, and/or frequency
of a sensor data provision is not sufficient for some aspect of the
system, to provide additional data to a machine learning algorithm,
and/or because a prior resource limitation is no longer applicable
and further data from one or more sensors is now available. An
example sensor data transmission protocol 12232 includes a command
to implement a multiplexing schedule 12318--for example where a
data collector 12208 and/or smart sensor is capable to multiplex
sensor data but does not do so under all operating conditions, or
only does so in response to the multiplexing schedule 12318 of the
sensor data transmission protocol 12232.
[1537] An example network management circuit 12230 further updates
the sensor data transmission protocol 12232 to adjust a network
transmission parameter (e.g., any network parameter 12276) for at
least a portion of the number of sensor values. For example,
certain network parameters that are not control variables and/or
are not currently being controlled are transmission conditions
12254, and certain network parameters are control variables and
subject to change in response to the data transmission protocol
12232, and/or the network management circuit 12230 can optionally
take control of certain network parameters to make them control
variables. An example network management circuit 12230 further
updates the sensor data transmission protocol 12232 to change any
one or more of: a frequency of data transmitted; a quantity of data
transmitted; a destination of data transmitted (including a target
or intermediate destination, and/or a routing); a network protocol
used to transmit the data; and/or a network path (e.g., providing a
redundant path to transmit the data (e.g., where high noise, high
network loss, and/or critical data are involved, the network
management circuit 12230 may determine that the system operations
are improved with redundant pathing for some of the data)). An
example network management circuit 12230 further updates the sensor
data transmission protocol 12232, such as to: bond an additional
network path to transmit the data (e.g., the network management
circuit 12230 may have authority to bring additional network
resources online, and/or selectively access additional network
resources); re-arrange a hierarchical network to transmit the data
(e.g., add or remove a hierarchy layer, change a parent-child
relationship, etc., for example, to provide critical data with
additional paths, fewer layers, and/or a higher priority path);
rebalance a hierarchical network to transmit the data; and/or
reconfigure a mesh network to transmit the data. An example network
management circuit 12230 further updates the sensor data
transmission protocol 12232 to delay a data transmission time,
and/or delay the data transmission time to a lower cost
transmission time.
[1538] An example network management circuit further updates the
sensor data transmission protocol 12232 to reduce the amount of
information sent at one time over the network and/or updates the
sensor data transmission protocol to adjust a frequency of data
sent from a second data collector (e.g., an offset data collector
within or not within the direct purview of the network management
circuit 12230, but where network resource utilization from the
second data collector competes with utilization of the first data
collector).
[1539] An example network management circuit 12230 further adjusts
an external data access frequency 12234--for example where the
expert system 12242 and/or the machine learning algorithm 12248
access external data 12246 to make continuous improvements to the
system (e.g., accessing information outside of the sensor data
values 12244, and/or from offset systems or aggregated cloud based
data), and/or an external data access timing (12236). The control
of external data 12246 access allows for control of network
utilization when the system is low on resources, when high fidelity
and/or frequency of sensor data values 12244 is prioritized, and/or
shifting of resource utilization into lower cost portions of the
operating space of the system. In certain embodiments, the system
collaboration circuit 12228 accesses the external data 12246, and
is responsive to the adjusted external data access frequency 12234
and/or external data access timing value 12236. An example network
management circuit 12230 further adjusts a network utilization
value 12238--for example to keep system utilization operations
below a threshold to reserve margin and/or to avoid the need for
capital cost upgrades to the system due to capacity limitations. An
example network management circuit 12230 adjusts the network
utilization value 12238 to utilize bandwidth at a lower cost
bandwidth time--for example when competing traffic is lower, when
network utilization does not adversely affect other system
processes, and/or when power consumption costs are lower.
[1540] An example network management circuit further 12230 enables
utilizing a high-speed network, and/or requests a higher cost
bandwidth access, for example when system process improvements are
sufficient that higher costs are justified, to meet a minimum
delivery requirement for data, and/or to move aging data from the
system before it becomes obsolete or must be deleted to make room
for subsequent data.
[1541] An example network management circuit 12230 further includes
an expert system 12242, where the updating the sensor data
transmission protocol 12232 is further in response to operations of
the expert system 12242. The self-organized, network-sensitive data
collection system may manage or optimize any such parameters or
factors noted throughout this disclosure, individually or in
combination, using an expert system, which may involve a rule-based
optimization, optimization based on a model of performance, and/or
optimization using machine learning/artificial intelligence,
optionally including deep learning approaches, or a hybrid or
combination of the above. Referencing FIG. 165, a number of
non-limiting examples of expert systems 12242, any one or more of
which may be present in embodiments having an expert system 12242.
Without limitation to any other aspect of the present disclosure
for expert systems, machine learning operations, and/or
optimization routines, example expert systems 12242 include a
rule-based system 12202 (e.g., seeded by rules based on modeling,
expert input, operator experience, or the like); a model-based
system 12204 (e.g., modeled responses or relationships in the
system informing certain operations of the expert system, and/or
working with other operations of the expert system); a neural-net
system (e.g., including rules, state machines, decision trees,
conditional determinations, and/or any other aspects); a
Bayesian-based system 12208 (e.g., statistical modeling, management
of probabilistic responses or relationships, and other
determinations for managing uncertainty); a fuzzy logic-based
system 12210 (e.g., determining fuzzification states for various
system parameters, state logic for responses, and de-fuzzification
of truth values, and/or other determinations for managing vague
states of the system); and/or a machine learning system 12212
(e.g., recursive, iterative, or other long-term optimization or
improvement of the expert system, including searching data,
resolutions, sampling rates, etc. that are not within the scope of
the expert system to determine if improved parameters are available
that are not presently utilized), which may be in addition to or an
embodiment of the machine learning algorithm 12248. Any aspect of
the expert system 12242 may be re-calibrated, deleted, and/or added
during operations of the expert system 12242, including in response
to updated information learned by the system, provided by a user or
operator, provided by the machine learning algorithm 12248,
information from external data 12246 and/or from offset
systems.
[1542] An example network management circuit 12230 further includes
a machine learning algorithm 12248, where updating the sensor data
transmission protocol 12232 is further in response to operations of
the machine learning algorithm 12248. An example machine learning
algorithm 12248 utilizes a machine learning optimization routine,
and upon determining that an improved sensor data transmission
protocol 12232 is available, the network management circuit 12230
provides the updated sensor data transmission protocol 12232 which
is utilized by the system collaboration circuit 12228. In certain
embodiments, the network management circuit 12230 may perform
various operations such as supplying a sensor data transmission
protocol 12232 which is utilized by the system collaboration
circuit 12228 to produce real-world results, applies modeling to
the system (either first principles modeling based on system
characteristics, a model utilizing actual operating data for the
system, a model utilizing actual operating data for an offset
system, and/or combinations of these) to determine what an outcome
of a given sensor data transmission protocol 12232 will be or would
have been (including, for example, taking extra sensor data beyond
what is utilized to support a process operated by the system,
and/or utilizing external data 12246 and/or benchmarking data
12240), and/or applying randomized changes to the sensor data
transmission protocol 12232 to ensure that an optimization routine
does not settle into a local optimum or non-optimal condition.
[1543] An example machine learning algorithm 12248 further utilizes
feedback data including the transmission conditions 12254, at least
a portion of the number of sensor values 12244; and/or where the
feedback data includes benchmarking data 12240. Referencing FIG.
172, non-limiting examples of benchmarking data 12240 are depicted.
Benchmarking data 12240 may reference, generally, expected data
(e.g., according to an expert system 12242, user input, prior
experience, and/or modeling outputs), data from an offset system
(including as adjusted for differences in the contemplated system
12200), aggregated data for similar systems (e.g., as external data
12246 which may be cloud-based), and the like. Benchmarking data
may be relative to the entire system, the network, a node on the
network, a data collector, and/or a single sensor or selected group
of sensors. Example and non-limiting benchmarking data includes a
network efficiency 12320 (e.g., throughput capability, power
utilization, quality and/or integrity of communications relative to
the infrastructure, load cycle, and/or environmental conditions of
the system 12200), a data efficiency 12322 (e.g., a percentage of
overall successful data captured relative to a target value, a
description of data gaps relative to a target value, and/or may be
focused on critical or prioritized data), a comparison with offset
data collectors 12324 (e.g., comparing data collectors in the
system having a similar environment, data collection
responsibility, or other characteristic making the comparison
meaningful), a throughput efficiency 12326 (e.g., a utilization of
the available throughput, a variability indicator--such as high
variability being an indication that a network may be oversized or
have further transmission capability, or high variability being an
indication that the network is responsive to cost avoidance
opportunities--or both depending upon the further context which can
be understood looking at other information such as why the
utilization differences occur), a data efficacy 12328 (e.g., a
determination that captured parameters are result effective, strong
control parameters, and/or highly predictive parameters, and that
efficacious data is taken at acceptable resolution, sampling rate,
and the like), a data quality 12330 (e.g., degradation of the data
due to noise, deconvolution errors, multiple calculation operations
and rounding, compression, packet losses, etc.), a data precision
12342 (e.g., a determination that sufficiently precise data is
taken, preserved during communications, and preserved during
storage), a data accuracy 12340 (e.g., a determination that
corrupted data, degradation through transmission and/or storage,
and/or time lag results in data that is alone inaccurate, or
inaccurate as applied in a time sequence or other configuration), a
data frequency 12338 (e.g., a determination that data as
communicated has sufficient time and/or frequency domain resolution
to determine the responses of interest), an environmental response
12336 (e.g., environmental effects on the network are sufficiently
managed to maintain other aspects of the data), a signal diversity
12332 (e.g., whether systematic gaps exist which increase the
consequences of degradation--e.g., 1% of the data is missing, but
it's systematically a single critical sensor; do critical sensed
parameters have multiple potential sources of information), a
critical response (is data sufficient to detect critical responses,
such as support for a sensor fusion operation and/or a pattern
recognition operation), and/or a mesh networking coherence 12334
(e.g., keeping processors, nodes, and other network aspects
together on a single view of applicable memory states).
[1544] Referencing FIG. 173, certain further non-limiting examples
of benchmarking data 12240 are depicted. Example and non-limiting
benchmarking data 12240 includes a data coverage 12346 (e.g., what
fraction of the desired data, critical data, etc. was successfully
communicated and captured; how is the data distributed throughout
the system), a target coverage 12344 (e.g., does a component or
process of the system have sufficient time and spatial resolution
of sensed values), a motion efficiency 12348 (e.g., reflecting an
amount of time, number of steps, or extent of motion required to
accomplish a given result, such as where an action is required by a
human operator, robotic element, drone, or the like to accomplish
an action), a quality of service commitment 12358 (e.g., an
agreement, formal or informal commitment, and/or best practice
quality of service such as maximum data gaps, minimum up-times,
minimum percentages of coverage), a quality of service guarantee
12360 (e.g., a formal agreement to a quality of service with known
or modeled consequences that can act in a cost function, etc.), a
service level agreement 12362 (e.g., minimum uptimes, data rates,
data resolutions, etc., which may be driven by industry practices,
regulatory requirements, and/or formal agreements that certain
parameters, detection for certain components, or detection for
certain processes in the system will meet data delivery
requirements in type, resolution, sample rate, etc.), a
predetermined quality of service value (e.g., a user-defined value,
a policy for the operator of the system, etc.), and/or a network
obstruction value 12364. Example and non-limiting network
obstruction values 12364 include a network interference value
(e.g., environmental noise, traffic on the network, collisions,
etc.), a network obstruction value (e.g., a component, operation,
and/or object obstructing wireless or wired communication in a
region of the network, or over the entire network), and/or an area
of impeded network connectivity (e.g., loss of connectivity for any
reason, which may be normal at least intermittently during
operations, or power loss, movement of objects through the area,
movement of a network node through the area (e.g., a smart phone
being utilized as a node), etc.). In certain embodiments, a network
obstruction value 12364 may be caused by interference from a
component of the system, an interference caused by one or more of
the sensors (e.g., due to a fault or failure, or operation outside
an expected range), interference caused by a metallic (or other
conductive) object, interference caused by a physical obstruction
(e.g., a dense object blocking or reducing transparency to wireless
transmissions); an attenuated signal caused by a low power
condition (e.g., a brown-out, scheduled power reduction, low
battery, etc.); and/or an attenuated signal caused by a network
traffic demand in a portion of the network (e.g., a node or group
of nodes has high traffic demand during operations of the
system).
[1545] Yet another example system includes an industrial system
including a number of components, and a number of sensors each
operatively coupled to at least one of the number of components; a
sensor communication circuit that interprets a number of sensor
data values from the number of sensors; a system collaboration
circuit that communicates at least a portion of the number of
sensor data values over a network having a number of nodes to a
storage target computing device according to a sensor data
transmission protocol; a transmission environment circuit that
determines transmission feedback corresponding to the communication
of the at least a portion of the number of sensor data values over
the network; and a network management circuit updates the sensor
data transmission protocol in response to the transmission
feedback. The example system collaboration circuit is further
responsive to the updated sensor data transmission protocol.
[1546] Referencing FIG. 167, an example apparatus 12256 for
self-organized, network-sensitive data collection in an industrial
environment for an industrial system having a network with a number
of nodes is depicted. In addition to the aspects of apparatus
12222, apparatus 12256 includes the system collaboration circuit
12228 further sending an alert to at least one of the number of
nodes (e.g., as a node communication 12258) in response to the
updated sensor data transmission protocol 12232. In certain
embodiments, updating the sensor data transmission protocol 12232
includes the network management circuit 12230 including node
control instructions, such as providing instructions to rearrange a
mesh network including the number of nodes, providing instructions
to rearrange a hierarchical data network including the number of
nodes, rearranging a peer-to-peer data network including the number
of nodes, rearranging a hybrid peer-to-peer data network including
the number of nodes. In certain embodiments, the system
collaboration circuit 12228 provides node control instructions as
one or more node communications 12258.
[1547] In certain embodiments, updating the sensor data
transmission protocol 12232 includes the network management circuit
12230 providing instructions to reduce a quantity of data sent over
the network; providing instructions to adjust a frequency of data
capture sent over the network; providing instructions to time-shift
delivery of at least a portion of the number of sensor values sent
over the network (e.g., utilizing intermediate storage); providing
instructions to change a network protocol corresponding to the
network; providing instructions to reduce a throughput of at least
one device coupled to the network; providing instructions to reduce
a bandwidth use of the network; providing instructions to compress
data corresponding to at least a portion of the number of sensor
values sent over the network; providing instructions to condense
data corresponding to at least a portion of the number of sensor
values sent over the network (e.g., providing a relevant subset,
reduced sample rate data, etc.); providing instructions to
summarize data (e.g., providing a statistical description, an
aggregated value, etc.) corresponding to at least a portion of the
number of sensor values sent over the network; providing
instructions to encrypt data corresponding to at least a portion of
the number of sensor values sent over the network (e.g., to enable
using an alternate, less secure network path, and/or to access
another network path requiring encryption); providing instructions
to deliver data corresponding to at least a portion of the number
of sensor values to a distributed ledger; providing instructions to
deliver data corresponding to at least a portion of the number of
sensor values to a central server (e.g., the plant computer 12210
and/or cloud server 12214); providing instructions to deliver data
corresponding to at least a portion of the number of sensor values
to a super-node; and providing instructions to deliver data
corresponding to at least a portion of the number of sensor values
redundantly across a number of network connections. In certain
embodiments, updating the sensor data transmission includes
providing instructions to deliver data corresponding to at least a
portion of the number of sensor values to one of the components
(e.g., where one or more components 12204 in the system has memory
storage and is communicatively accessible to the sensor 12206, the
data collector 12208, and/or the network), and/or where the one of
the components is communicatively coupled to the sensor providing
the data corresponding to at least a portion of the number of
sensor values (e.g., where the data to be stored on the component
12204 is the component the data was measured for, or is in
proximity to the sensor 12206 taking the data).
[1548] An example network includes a mesh network where the network
management circuit 12230 further updates the sensor data
transmission protocol 12232 to provide instructions to eject (e.g.,
remove from the mesh map, take it out of service, etc.) one of the
number of nodes from the mesh network. An example network includes
a peer-to-peer network, where the network management circuit 12230
further updates the sensor data transmission protocol 12232 to
provide instructions to eject one of the number of nodes from the
peer-to-peer network.
[1549] An example network management circuit 12230 further updates
the sensor data transmission protocol 12232 to cache (e.g., as a
sensor data cache 12260) at least a portion of the number of sensor
values 12252. In certain further embodiments, the network
management circuit 12230 further updates the sensor data
transmission protocol 12232 to communicate the cached sensor values
12260 in response to at least one of: a determination that the
cached data is requested (e.g., a user, model, machine learning
algorithm, expert system, etc. has requested the data); a
determination that the network feedback indicates communication of
the cached data is available (e.g., a prior limitation on the
network leading the network management circuit 12230 to direct
caching is now lifted or improved); and/or a determination that
higher priority data is present that requires utilization of cache
resources holding the cached data 12260.
[1550] An example system 12200 for self-organized,
network-sensitive data collection in an industrial environment
includes an industrial system 12202 having a number of components
12204 and a number of sensors 12206 each operatively coupled to at
least one of the number of components 12204. A sensor communication
circuit 12224 interprets the number of sensor data values 12244
from the number of sensors at a predetermined frequency. The system
collaboration circuit 12228 that communicates at least a portion of
the number of sensor data values 12252 over a network having a
number of nodes to a storage target computing device according to
the sensor data transmission protocol 12232, where the sensor data
transmission protocol 12232 includes a predetermined hierarchy of
data collection and the predetermined frequency. An example data
management circuit 12230 adjusts the predetermined frequency in
response to transmission conditions 12254, and/or in response to
benchmarking data 12240.
[1551] An example system 12200 for self-organized,
network-sensitive data collection in an industrial environment
includes an industrial system 12202 having a number of components
12204, and a number of sensors 12206 each operatively coupled to at
least one of the number of components 12204. The sensor
communication circuit 12224 interprets a number of sensor data
values 12244 from the number of sensors 12206 at a predetermined
frequency, and the system collaboration circuit 12228 communicates
at least a portion of the number of sensor data values 12252 over a
network having a number of nodes to a storage target computing
device according to a sensor data transmission protocol. A
transmission environment circuit 12226 determines transmission
feedback (e.g., transmission conditions 12254) corresponding to the
communication of the at least a portion of the number of sensor
data values 12252 over the network. A network management circuit
12230 updates the sensor data transmission protocol 12232 in
response to the transmission feedback 12254, and a network
notification circuit 12268 provides an alert value 12264 in
response to the updated sensor data transmission protocol 12232.
Example alert values 12264 include a notification to an operator, a
notification to a user, a notification to a portable device
associated with a user, a notification to a node of the network, a
notification to a cloud computing device, a notification to a plant
computing device, and/or a provision of the alert as external data
to an offset system. Example and non-limiting alert conditions
include a component of the system operating in a fault condition, a
process of the system operating in a fault condition, a
commencement of the utilization of cache storage and/or
intermediate storage for sensor values due to a network
communication limit, a change in the sensor data transmission
protocol (including changes of a selected type), and/or a change in
the sensor data transmission protocol that may result in loss of
data fidelity or resolution (e.g., compression of data, condensing
of data, and/or summarizing data).
[1552] An example transmission feedback includes a feedback value
such as: a change in transmission pricing, a change in storage
pricing, a loss of connectivity, a reduction of bandwidth, a change
in connectivity, a change in network availability, a change in
network range, a change in wide area network (WAN) connectivity,
and/or a change in wireless local area network (WLAN)
connectivity.
[1553] An example system includes an assembly line industrial
system having a number of vibrating components, such as motors,
conveyors, fans, and/or compressors. The system includes a number
of sensors that determine various parameters related to the
vibrating components, including determination of diagnostic and/or
process related information (proper operation, off-nominal
operation, operating speed, imminent servicing or failure, etc.) of
one or more of the components. Example sensors, without limitation,
include noise, vibration, acceleration, temperature, and/or shaft
speed sensors. The sensor information is conveyed to a target
storage system, including at least partially through a network
communicatively coupled to the assembly line industrial system. The
example system includes a network management circuit that
determines a sensor data transmission protocol to control flow of
data from the sensors to the target storage system. The network
management circuit, a related expert system, and/or a related
machine learning algorithm, updates the sensor data transmission
protocol to ensure efficient network utilization, sufficient
delivery of data to support system control, diagnostics, and/or
other determinations planned for the data outside of the system, to
reduce resource utilization of data transmission, and/or to respond
to system noise factors, variability, and/or changes in the system
or related aspects such as cost or environment parameters. The
example system includes improvement of system operations to ensure
that diagnostics, controls, or other data dependent operations can
be completed, to reduce costs while maintaining performance, and/or
to increase system capability over time or process cycles.
[1554] An example system includes an automated robotic handling
system, including a number of components such as actuators, gear
boxes, and/or rail guides. The system includes a number of sensors
that determine various parameters related to the components,
including without limitation actuator position and/or feedback
sensors, vibration, acceleration, temperature, imaging sensors,
and/or spatial position sensors (e.g., within the handling system,
a related plant, and/or GPS-type positioning). The sensor
information is conveyed to a target storage system, including at
least partially through a network communicatively coupled to the
automated robotic handling system. The example system includes a
network management circuit that determines a sensor data
transmission protocol to control flow of data from the sensors to
the target storage system. The network management circuit, a
related expert system, and/or a related machine learning algorithm,
updates the sensor data transmission protocol to ensure efficient
network utilization, sufficient delivery of data to support system
control, diagnostics, improvement and/or efficiency updates to
handling efficiency, and/or other determinations planned for the
data outside of the system, to reduce resource utilization of data
transmission, and/or to respond to system noise factors,
variability, and/or changes in the system or related aspects such
as cost or environment parameters. The example system includes
improvement of system operations to ensure that diagnostics,
controls, or other data dependent operations can be completed, to
reduce costs while maintaining performance, and/or to increase
system capability over time or process cycles.
[1555] An example system includes a mining operation, including a
surface and/or underground mining operation. The example mining
operation includes components such as an underground inspection
system, pumps, ventilation, generators and/or power generation, gas
composition or quality systems, and/or process stream composition
systems (e.g., including determination of desired material
compositions, and/or composition of effluent streams for pollution
and/or regulatory control). Various sensors are present in an
example system to support control of the operation, determine
status of the components, support safe operation, and/or to support
regulatory compliance. The sensor information is conveyed to a
target storage system, including at least partially through a
network communicatively coupled to the mining operation. In certain
embodiments, the network infrastructure of the mining operation
exhibits high variability, due to, without limitation, significant
environmental variability (e.g., pit or shaft condition
variability) and/or intermittent availability--e.g., shutting off
electronics during certain mining operations, difficulty in
providing network access to portions of the mining operation,
and/or the desirability to include mobile or intermittently
available devices within the network infrastructure. The example
system includes a network management circuit that determines a
sensor data transmission protocol to control flow of data from the
sensors to the target storage system. The network management
circuit, a related expert system, and/or a related machine learning
algorithm, updates the sensor data transmission protocol to ensure
efficient network utilization, sufficient delivery of data to
support system control, diagnostics, improvement and/or efficiency
updates to handling efficiency, support for financial and/or
regulatory compliance, and/or other determinations planned for the
data outside of the system, to reduce resource utilization of data
transmission, and/or to respond to system noise factors,
variability, network infrastructure challenges, and/or changes in
the system or related aspects such as cost or environment
parameters.
[1556] An example system includes an aerospace system, such as a
plane, helicopter, satellite, space vehicle or launcher, orbital
platform, and/or missile. Aerospace systems have numerous systems
supported by sensors, such as engine operations, control surface
status and vibrations, environmental status (internal and
external), and telemetry support. Additionally, aerospace systems
have high variability in both the number of sensors of varying
types (e.g., a small number of fuel pressure sensors, but a large
number of control surface sensors) as well as the sampling rates
for relevant determinations of sensors of varying types (e.g.,
1-second data may be sufficient for internal cabin pressure, but
weather radar or engine speed sensors may require much higher time
resolution). Computing power on an aerospace application is at a
premium due to power consumption and weight considerations, and
accordingly iterative, recursive, deep learning, expert system,
and/or machine learning operations to improve any systems on the
aerospace system, including sensor data taking and transmission of
sensor information, are driven in many embodiments to computing
devices outside of the aerospace vehicle of the system (e.g.,
through offline learning, post-processing, or the like). Storage
capacity on an aerospace application is similarly at a premium,
such that long-term storage of sensor data on the aerospace vehicle
is not a cost-effective solution for many embodiments.
Additionally, network communication from an aerospace vehicle may
be subject to high variability and/or bandwidth limitations as the
vehicle moves rapidly through the environment and/or into areas
where direct communication with ground-based resources is not
practical. Further, certain aerospace applications have significant
competition for available network resources--for example in
environments with a large number of passengers where passenger
utilization of a network infrastructure consumes significant
bandwidth. Accordingly, it can be seen that operations of a network
management circuit, a related expert system, and/or a related
machine learning algorithm, to update the sensor data transmission
protocol can significantly enhance sensing operations in various
aerospace systems. Additionally, certain aerospace applications
have a high number of offset systems, enhancing the ability of an
expert system or machine learning algorithm to improve sensor data
capture and transmission operations, and/or to manage the high
variability in sensed parameters (frequency, data rate, and/or data
resolution) for the system across operating conditions.
[1557] An example system includes an oil or gas production system,
such as a production platform (onshore or offshore), pumps, rigs,
drilling equipment, blenders, and the like. Oil and gas production
systems exhibit high variability in sensed variable types and
sensing parameters, such as vibration (e.g., pumps, rotating
shafts, fluid flow through pipes, etc.--which may be high frequency
or low frequency), gas composition (e.g., of a wellhead area,
personnel zone, near storage tanks, etc. --where low frequency may
typically be acceptable, and/or it may be acceptable that no data
is taken during certain times such as when personnel are not
present), and/or pressure values (which may vary significantly both
in required resolution and frequency or sampling rate depending
upon operations currently occurring in the system). Additionally,
oil and gas production systems have high variability in network
infrastructure, both according to the system (e.g., an offshore
platform versus a long-term ground-based production facility) and
according to the operations being performed by the system (e.g., a
wellhead in production may have limited network access, while a
drilling or fracturing operation may have significant network
infrastructure at a site during operations). Accordingly, it can be
seen that operations of a network management circuit, a related
expert system, and/or a related machine learning algorithm, to
update the sensor data transmission protocol can significantly
enhance sensing operations in various oil or gas production
systems.
[1558] The present disclosure describes system for self-organized,
network-sensitive data collection in an industrial environment, the
system according to one disclosed non-limiting embodiment of the
present disclosure can include an industrial system including a
plurality of components, and a plurality of sensors each
operatively coupled to at least one of the plurality of components,
a sensor communication circuit structured to interpret a plurality
of sensor data values from the plurality of sensors, a system
collaboration circuit structured to communicate at least a portion
of the plurality of sensor data values to a storage target
computing device according to a sensor data transmission protocol,
a transmission environment circuit structured to determine
transmission conditions corresponding to the communication of the
at least a portion of the plurality of sensor data values to the
storage target computing device, a network management circuit
structured to update the sensor data transmission protocol in
response to the transmission conditions, and wherein the system
collaboration circuit is further responsive to the updated sensor
data transmission protocol.
[1559] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission conditions include environmental conditions relating
to sensor communication of the plurality of sensor data values, and
wherein the network management circuit is further structured to
analyze the environmental conditions, and wherein updating the
sensor data transmission protocol includes modifying the manner in
which the plurality of sensor data values is transmitted from the
plurality of sensors to the storage target computing device.
[1560] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein a data
collector communicatively coupled to at least a portion of the
plurality of sensors and responsive to the sensor data transmission
protocol, wherein the system collaboration circuit is structured to
receive the plurality of sensor data values from the at least a
portion of the plurality of sensors, and wherein the transmission
conditions correspond to at least one network parameter
corresponding to the communication of the plurality of sensor data
values from the at least a portion of the plurality of sensors.
[1561] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to modify the data collector to adjust a data
collection rate for at least one of the plurality of sensors.
[1562] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to modify a multiplexing schedule of the data
collector.
[1563] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to command an intermediate storage operation
for at least a portion of the plurality of sensor data values.
[1564] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to command further data collection for at
least a portion of the plurality of sensors.
[1565] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to modify the data collector to implement a
multiplexing schedule.
[1566] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to adjust a network transmission parameter
for at least a portion of the plurality of sensor values.
[1567] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the adjusted
network transmission parameter includes at least one parameter
selected from the parameters consisting of a timing parameter, a
protocol selection, a file type selection, a streaming parameter
selection, and a compression parameter.
[1568] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to change a frequency of data
transmitted.
[1569] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to change a quantity of data transmitted.
[1570] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to change a destination of data
transmitted.
[1571] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to change a network protocol used to transmit
the data.
[1572] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to add a redundant network path to transmit
the data.
[1573] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to bond an additional network path to
transmit the data.
[1574] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to re-arrange a hierarchical network to
transmit the data.
[1575] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to rebalance a hierarchical network to
transmit the data.
[1576] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to reconfigure a mesh network to transmit the
data.
[1577] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to delay a data transmission time.
[1578] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to delay the data transmission time to a
lower cost transmission time.
[1579] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to reduce the amount of information sent at
one time over the network.
[1580] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to adjust a frequency of data sent from a
second data collector.
[1581] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to adjust an external data
access frequency, and wherein the system collaboration circuit is
responsive to the adjusted external data access frequency.
[1582] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to adjust an external data
access timing value, and wherein the system collaboration circuit
is responsive to the adjusted external data access timing
value.
[1583] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to adjust a network
utilization value.
[1584] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to adjust the network
utilization value to utilize bandwidth at a lower cost bandwidth
time.
[1585] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to enable utilizing a
high-speed network.
[1586] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to request a higher cost
bandwidth access, and to update the sensor transmission protocol in
response to the higher cost bandwidth access.
[1587] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit further includes an expert system, and wherein
the updating the sensor data transmission protocol is further in
response to operations of the expert system.
[1588] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit further includes a machine learning algorithm,
and wherein the updating the sensor data transmission protocol is
further in response to operations of the machine learning
algorithm.
[1589] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the machine
learning algorithm is further structured to utilize feedback data
including the transmission conditions.
[1590] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the feedback
data further includes at least a portion of the plurality of sensor
values.
[1591] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the feedback
data further includes benchmarking data.
[1592] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of: a network efficiency, a data efficiency, a
comparison with offset data collectors, a throughput efficiency, a
data efficacy, a data quality, a data precision, a data accuracy,
and a data frequency.
[1593] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of: an environmental response, a mesh networking
coherence, a data coverage, a target coverage, a signal diversity,
a critical response, and a motion efficiency.
[1594] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission conditions corresponding to the communication comprise
at least one condition selected from the conditions consisting of a
mesh network needs to rearrange to balance throughput, a parent
node in a hierarchically arranged network has had a change in
connectivity, a network super-node in a hybrid peer-to-peer
application-layer network has been replaced, and a node in a mesh
or hierarchical network has been detected as malicious.
[1595] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission conditions corresponding to the communication comprise
at least one condition selected from the conditions consisting of a
mesh network peer forwarding packets has lost connectivity, a mesh
network peer forwarding packets has gained additional bandwidth, a
mesh network peer forwarding packets has had a reduction in
bandwidth, and a mesh network peer forwarding packets has regained
connectivity.
[1596] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission conditions corresponding to the communication comprise
at least one condition selected from the conditions consisting of a
cost of transmitting information has changed dynamically, a change
has been made in a hierarchical network arrangement to balance
bandwidth use in a network tree, a portion of the network relaying
sampling data has had a change in permissions, authorization level,
or credentials, a current cost of delivering information over a
network hop has changed, a higher-bandwidth network connection type
has become available, a lower-cost network connection type has
become available, and a change has been made in a network
topology.
[1597] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission conditions corresponding to the communication include
at least one condition selected from the conditions consisting of a
data collection client has changed a data frequency requirement for
at least one of the plurality of sensor values, a data collection
client has changed a data type requirement for at least one of the
plurality of sensor values, a data collection client has changed a
sensor target for data collection, and a data collection client has
changed the storage target computing device.
[1598] The present disclosure describes system for self-organized,
network-sensitive data collection in an industrial environment, the
system according to one disclosed non-limiting embodiment of the
present disclosure can include an industrial system including a
plurality of components, and a plurality of sensors each
operatively coupled to at least one of the plurality of components,
a sensor communication circuit structured to interpret a plurality
of sensor data values from the plurality of sensors, a system
collaboration circuit structured to communicate at least a portion
of the plurality of sensor data values over a network having a
plurality of nodes to a storage target computing device according
to a sensor data transmission protocol, a transmission environment
circuit structured to determine transmission feedback corresponding
to the communication of the at least a portion of the plurality of
sensor data values over the network, and a network management
circuit structured to update the sensor data transmission protocol
in response to the transmission feedback, wherein the system
collaboration circuit is further responsive to the updated sensor
data transmission protocol.
[1599] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the system
collaboration circuit is further structured to send an alert to at
least one of the plurality of nodes in response to the updated
sensor data transmission protocol.
[1600] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein updating the
sensor data transmission includes at least one operation selected
from the operations consisting of providing instructions to
rearrange a mesh network including the plurality of nodes,
providing instructions to rearrange a hierarchical data network
including the plurality of nodes, rearranging a peer-to-peer data
network including the plurality of nodes and rearranging a hybrid
peer-to-peer data network including the plurality of nodes.
[1601] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein updating the
sensor data transmission includes at least one operation selected
from the operations consisting of providing instructions to reduce
a quantity of data sent over the network, providing instructions to
adjust a frequency of data capture sent over the network, providing
instructions to time-shift delivery of at least a portion of the
plurality of sensor values sent over the network, and providing
instructions to change a network protocol corresponding to the
network.
[1602] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein updating the
sensor data transmission includes at least one operation selected
from the operations consisting of providing instructions to reduce
a throughput of at least one device coupled to the network,
providing instructions to reduce a bandwidth use of the network,
providing instructions to compress data corresponding to at least a
portion of the plurality of sensor values sent over the network,
providing instructions to condense data corresponding to at least a
portion of the plurality of sensor values sent over the network,
providing instructions to summarize data corresponding to at least
a portion of the plurality of sensor values sent over the network,
and providing instructions to encrypt data corresponding to at
least a portion of the plurality of sensor values sent over the
network.
[1603] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein updating the
sensor data transmission includes at least one operation selected
from the operations consisting of providing instructions to deliver
data corresponding to at least a portion of the plurality of sensor
values to a distributed ledger, providing instructions to deliver
data corresponding to at least a portion of the plurality of sensor
values to a central server, providing instructions to deliver data
corresponding to at least a portion of the plurality of sensor
values to a super-node and providing instructions to deliver data
corresponding to at least a portion of the plurality of sensor
values redundantly across a plurality of network connections.
[1604] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein updating the
sensor data transmission includes providing instructions to deliver
data corresponding to at least a portion of the plurality of sensor
values to one of the plurality of components.
[1605] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the one of
the plurality of components is communicatively coupled to the
sensor providing the data corresponding to at least a portion of
the plurality of sensor values.
[1606] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the system
collaboration circuit is further structured to interpret a quality
of service commitment, and wherein the network management circuit
is further structured to update the sensor data transmission
protocol further in response to the quality of service
commitment.
[1607] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the system
collaboration circuit is further structured to interpret a service
level agreement, and wherein the network management circuit is
further structured to update the sensor data transmission protocol
further in response to the service level agreement.
[1608] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to provide instructions to increase a quality
of service value.
[1609] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
includes a mesh network, and wherein the network management circuit
is further structured to update the sensor data transmission
protocol to provide instructions to eject one of the plurality of
nodes from the mesh network.
[1610] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
includes a peer-to-peer network, and wherein the network management
circuit is further structured to update the sensor data
transmission protocol to provide instructions to eject one of the
plurality of nodes from the peer-to-peer network.
[1611] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to cache at least a portion of the plurality
of sensor values.
[1612] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit is further structured to update the sensor data
transmission protocol to communicate the cached at least a portion
of the plurality of sensor values in response to at least one of a
determination that the cached data is requested, a determination
that the network feedback indicates communication of the cached
data is available, and a determination that higher priority data is
present that requires utilization of cache resources holding the
cached data.
[1613] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the system
further includes a data collector configured to receive the at
least a portion of the plurality of sensor data values, wherein the
at least a portion of the plurality of sensor data values includes
data provided by a plurality of the sensors, and wherein the
transmission feedback includes network performance information
corresponding to the data collector.
[1614] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the system
further includes a data collector configured to receive the at
least a portion of the plurality of sensor data values, wherein the
at least a portion of the plurality of sensor data values includes
data provided by a plurality of the sensors, a second data
collector communicatively coupled to the network, and wherein the
transmission feedback includes network performance information
corresponding to the second data collector.
[1615] The present disclosure describes system for self-organized,
network-sensitive data collection in an industrial environment, the
system according to one disclosed non-limiting embodiment of the
present disclosure can include an industrial system including a
plurality of components, and a plurality of sensors each
operatively coupled to at least one of the plurality of components,
a sensor communication circuit structured to interpret a plurality
of sensor data values from the plurality of sensors at a
predetermined frequency, a system collaboration circuit structured
to communicate at least a portion of the plurality of sensor data
values over a network having a plurality of nodes to a storage
target computing device according to a sensor data transmission
protocol, the sensor data transmission protocol including a
predetermined hierarchy of data collection and the predetermined
frequency, a transmission environment circuit structured to
determine transmission feedback corresponding to the communication
of the at least a portion of the plurality of sensor data values
over the network, and a network management circuit structured to
update the sensor data transmission protocol in response to the
transmission feedback and further in response to benchmarking data,
wherein the system collaboration circuit is further responsive to
the updated sensor data transmission protocol.
[1616] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein updating the
sensor data transmission includes at least one operation selected
from the operations consisting of providing an instruction to
change the sensors of the plurality of sensors, providing an
instruction to adjust the predetermined frequency, providing an
instruction to adjust a quantity of the plurality of sensor data
values that are stored, providing an instruction to adjust a data
transmission rate of the communication of the at least a portion of
the plurality of sensor data values, providing an instruction to
adjust a data transmission time of the communication of the at
least a portion of the plurality of sensor data values, and
providing an instruction to adjust a networking method of the
communication over the network.
[1617] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of a network efficiency, a data efficiency, a comparison
with offset data collectors, a throughput efficiency, a data
efficacy, a data quality, a data precision, a data accuracy, and a
data frequency.
[1618] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of an environmental response, a mesh networking
coherence, a data coverage, a target coverage, a signal diversity,
a critical response, and a motion A further embodiment of any of
the foregoing embodiments of the present disclosure may include
situations wherein the benchmarking data further includes data
selected from the list consisting of a quality of service
commitment, a quality of service guarantee, a service level
agreement, and a predetermined quality of service value.
[1619] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of a network interference value, a network obstruction
value, and an area of impeded network connectivity.
[1620] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission feedback includes a communication interference value
selected from the values consisting of an interference caused by a
component of the system, an interference caused by one of the
sensors, an interference caused by a metallic object, an
interference caused by a physical obstruction, an attenuated signal
caused by a low power condition, and an attenuated signal caused by
a network traffic demand in a portion of the network.
[1621] The present disclosure describes a system for
self-organized, network-sensitive data collection in an industrial
environment, the system according to one disclosed non-limiting
embodiment of the present disclosure can include an industrial
system including a plurality of components, and a plurality of
sensors each operatively coupled to at least one of the plurality
of components, a sensor communication circuit structured to
interpret a plurality of sensor data values from the plurality of
sensors at a predetermined frequency, a system collaboration
circuit structured to communicate at least a portion of the
plurality of sensor data values over a network having a plurality
of nodes to a storage target computing device according to a sensor
data transmission protocol, a transmission environment circuit
structured to determine transmission feedback corresponding to the
communication of the at least a portion of the plurality of sensor
data values over the network, a network management circuit
structured to update the sensor data transmission protocol in
response to the transmission feedback and a network notification
circuit structured to provide an alert value in response to the
updated sensor data transmission protocol, wherein the system
collaboration circuit is further responsive to the updated sensor
data transmission protocol.
[1622] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
transmission feedback includes at least one feedback value selected
from the values consisting of: a change in transmission pricing, a
change in storage pricing, a loss of connectivity, a reduction of
bandwidth, a change in connectivity, a change in network
availability, a change in network range, a change in wide area
network (WAN) connectivity, and a change in wireless local area
network (WLAN) connectivity.
[1623] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit further includes an expert system, and wherein
the updating the sensor data transmission protocol is further in
response to operations of the expert system.
[1624] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system includes at least one system selected from the systems
consisting of: a rule-based system, a model-based system, a
neural-net system, a Bayesian-based system, a fuzzy logic-based
system, and a machine learning system.
[1625] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the network
management circuit further includes a machine learning algorithm,
and wherein the updating the sensor data transmission protocol is
further in response to operations of the machine learning
algorithm.
[1626] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the machine
learning algorithm is further structured to utilize feedback data
including the transmission conditions.
[1627] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the feedback
data further includes at least a portion of the plurality of sensor
values.
[1628] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the feedback
data further includes benchmarking data.
[1629] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of: a network efficiency, a data efficiency, a
comparison with offset data collectors, a throughput efficiency, a
data efficacy, a data quality, a data precision, a data accuracy,
and a data frequency.
[1630] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
benchmarking data further includes data selected from the list
consisting of: an environmental response, a mesh networking
coherence, a data coverage, a target coverage, a signal diversity,
a critical response, and a motion efficiency.
[1631] Referencing FIG. 174, an example system 12500 for data
collection in an industrial environment includes an industrial
system 12502 having a number of components 12504, and a number of
sensors 12506, wherein each of the sensors 12506 is operatively
coupled to at least one of the components 12504. The selection,
distribution, type, and communicative setup of sensors depends upon
the application of the system 12500 and/or the context.
[1632] The example system 12500 further includes a sensor
communication circuit 12522 (reference FIG. 185) that interprets a
number of sensor data values 12542. An example system includes the
sensor data values 12542 being a number of values to support a
sensor fusion operation, for example a set of sensors believed to
encompass detection of operating conditions of the system that
affect a desired output, to control a process or portion of the
industrial system 12502, to diagnose or predict an aspect of the
industrial system 12502 or a process associated with the industrial
system industrial system 12502.
[1633] In certain embodiments, sensor data values 12542 are
provided to a data collector 12508, which may be in communication
with multiple sensors 12506 and/or with a controller 12512. In
certain embodiments, a plant computer 12510 is additionally or
alternatively present. In the example system, the controller 12512
is structured to functionally execute operations of the sensor
communication circuit 12522, sensor data storage profile circuit
12524, sensor data storage implementation circuit 12526, storage
planning circuit 12528, and/or haptic feedback circuit 12530. The
controller 12512 is depicted as a separate device for clarity of
description. Aspects of the controller 12512 may be present on the
sensors 12506, the data controller 12508, the plant computer 12510,
and/or on a cloud computing device 12514. In certain embodiments
described throughout this disclosure, all aspects of the controller
12512 or other controllers may be present in another device
depicted on the system 12500. The plant computer 12510 represents
local computing resources, for example processing, memory, and/or
network resources, that may be present and/or in communication with
the industrial system 12500. In certain embodiments, the cloud
computing device 12514 represents computing resources externally
available to the industrial system 12502, for example over a
private network, intra-net, through cellular communications,
satellite communications, and/or over the internet. In certain
embodiments, the data controller 12508 may be a computing device, a
smart sensor, a MUX box, or other data collection device capable to
receive data from multiple sensors and to pass-through the data
and/or store data for later transmission. An example data
controller 12508 has no storage and/or limited storage, and
selectively passes sensor data therethrough, with a subset of the
sensor data being communicated at a given time due to bandwidth
considerations of the data controller 12508, a related network,
and/or imposed by environmental constraints. In certain
embodiments, one or more sensors and/or computing devices in the
system 12500 are portable devices--for example a plant operator
walking through the industrial system may have a smart phone, which
the system 12500 may selectively utilize as a data controller
12508, sensor 12506--for example to enhance communication
throughput, sensor resolution, and/or as a primary method for
communicating sensor data values 12542 to the controller 12512. The
system 12500 depicts the controller 12512, the sensors 12506, the
data controller 12508, the plant computer 12510, and/or the cloud
computing device 12514 having a memory storage for storing sensor
data thereon, any one or more of which may not have a memory
storage for storing sensor data thereon. In certain embodiments,
the sensor data storage profile circuit 12524 prepares a data
storage profile 12532 that directs sensor data to memory storage,
including moving sensor data in a controlled manner from one memory
storage to another. Sensor data stored on various devices consumes
memory on the device, transferring the stored data between device
consumes network and/or communication bandwidth in the system
12500, and/or operations on sensor data such as processing,
compression, statistical analysis, summarization, and/or provision
of alerts consumes processor cycles as well as memory to support
operations such as buffer files, intermediate data, and the like.
Accordingly, improved or optimal configuration and/or updating of
the data storage profile 12532 provides for lower utilization of
system resources and/or allows for the storage of sensor data with
higher resolution, over longer time frames, and/or from a larger
number of sensors.
[1634] Referencing FIG. 175, an example apparatus 12520 for
self-organizing data storage for a data collector for an industrial
system is depicted. An example apparatus 12520 includes a
controller, such as controller 12512. The example controller
includes a sensor communication circuit 12522 that interprets a
number of sensor data values 12542, and a sensor data storage
profile circuit 12524 that determines a data storage profile 12532.
The data storage profile 12532 includes a data storage plan for the
number of sensor data values 12542. The data storage plan includes
how much of the sensor data values 12542 is stored initially (e.g.,
as the data is sampled, and/or after initial transmission to a data
controller 12508, plant computer 12510, controller 12512, and/or
cloud-computing device 12514). The example data storage profile
12532 includes a plan for the transmission of data, which may be
according to a time, a process stage, operating conditions of the
system 12500 and/or a network related to the system, as well as the
communication conditions of devices within the system 12500.
[1635] For example, data from a temperature sensor may be planned
to be stored locally on a sensor having storage capacity, and
transmitted in bursts to a data controller. The data controller may
be instructed to transmit the sensor data to the cloud computing
device on a schedule, for example as the data controller memory
reaches a threshold, as network communication capacity is
available, at the conclusion of a process, and/or upon request.
Additionally or alternatively, data from the sensors may be changed
on a device or upon transfer of the data (e.g., just before
transfer, just after transfer, or on a schedule). For example, the
data storage profile 12532 may describe storing high resolution,
high precision, and/or high-sampling rate data, and reducing the
storage of the data set after a period of time, a selected event,
and/or confirmation of a successful process or that the high
resolution data is no longer needed. Accordingly, higher resolution
data and/or data from a large number of sensors may be available
for utilization, such as by a sensor fusion operation or the like,
while the long-term memory utilization is also managed. Each of the
sensor data sets may be treated individually for memory storage
characteristics, and/or sensors may be grouped for similar
treatment (e.g., sensors having similar data characteristics and/or
impact on the system, sensors cooperating in a sensor fusion
operation, a group of sensors utilized for a model or a virtual
sensor, etc.). In certain embodiments, sensor data from a single
sensor may be treated distinctly according to an update of the data
storage profile 12532, a time or process stage at which the data is
taken, and/or a system condition such as a network issue, a fault
condition, or the like. Additionally or alternatively, a single set
of sensor data may be stored in multiple places in the system, for
example where the same data is utilized in several separate sensor
fusion operations, and the resource consumption from storing
multiple sets of the same data is lower than a processor or network
utilization to utilize a single stored data set in several separate
processes.
[1636] Referencing FIG. 179, various aspects of an example data
storage profile 12532 are depicted. The example data storage
profile 12532 includes aspects of the data storage profile 12532
that may be included as additional or alternative aspects of the
data storage profile 12532 relative to the storage location
definition 12534, the storage time definition, and/or the storage
time definition 12536, data resolution description 12540, and/or
may be included as aspects of these. Any one or more of the factors
or parameters relating to storage depicted in FIG. 179 may be
included in a data storage profile 12532 and/or managed by a
self-organizing storage system (e.g., system 12500 and/or
controller 12532). The self-organizing storage system may manage or
optimize any such parameters or factors noted throughout this
disclosure, individually or in combination, using an expert system,
which may involve a rule-based optimization, optimization based on
a model of performance, and/or optimization using machine
learning/artificial intelligence, optionally including deep
learning approaches, or a hybrid or combination of the above. In
embodiments, an example data storage profile 12532 includes a
storage type plan 12576 or profile that accounts for or specifies a
type of storage, such as based on the underlying physical media
type of the storage, the type of device or system on which storage
resides, the mechanism by which storage can be accessed for reading
or writing data, or the like. For example, a storage media plan
12578 may specify or account for use of tape media, hard disk drive
media, flash memory media, non-volatile memory, optical media,
one-time programmable memory, or the like. The storage media plan
may account for or specify parameters relating to the media,
including capabilities such as storage duration, power usage,
reliability, redundancy, thermal performance factors, robustness to
environmental conditions (such as radiation or extreme
temperatures), input/output speeds and capabilities, writing
speeds, reading speeds, and the like, or other media specific
parameters such as data file organization, operating system,
read-write life cycle, data error rates, and/or data compression
aspects related to or inherent to the media or media controller. A
storage access plan 12580 or profile may specify or account for the
nature of the interface to available storage, such as database
storage (including relational, object-oriented, and other
databases, as well as distributed databases, virtual machines,
cloud-based databases, and the like), cloud storage (such as S3.TM.
buckets and other simple storage formats), stream-based storage,
cache storage, edge storage (e.g., in edge-based network nodes),
on-device storage, server-based storage, network-attached storage
or the like. The storage access plan or profile may specify or
account for factors such as the cost of different storage types,
input/output performance, reliability, complexity, size, and other
factors. A storage protocol plan 12582 or profile may specify or
account for a protocol by which data will be transmitted or
written, such as a streaming protocol, an IP-based protocol, a
non-volatile memory express protocol, a SATA protocol or other
network-attached storage protocol, a disk-attached storage
protocol, an Ethernet protocol, a peered storage protocol, a
distributed ledger protocol, a packet-based storage protocol, a
batch-based storage protocol, a metadata storage protocol, a
compressed storage protocol (using various compression types, such
as for packet-based media, streaming media, lossy or lossless
compression types, and the like), or others. The storage protocol
plan may account for or specify factors relating to the storage
protocol, such as input/output performance, compatibility with
available network resources, cost, complexity, data processing
required to implement the protocol, network utilization to support
the protocol, robustness of the protocol to support system noise
(e.g., EM, competing network traffic, interruption frequency of
network availability), memory utilization to implement the protocol
(such as: as-stored memory utilization, and/or intermediate memory
utilization in creating or transferring the data), and the like. A
storage writing protocol 12584 plan or profile may specify or
account for how data will be written to storage, such as in file
form, in streaming form, in batch form, in discrete chunks, to
partitions, in stripes or bands across different storage locations,
in streams, in packets or the like. The storage writing protocol
may account for or specify parameters and factors relating to
writing, such as input speed, reliability, redundancy, security,
and the like. A storage security plan 12586 or profile may account
for or specify how storage will be secured, such as availability or
type of password protection, authentication, permissioning, rights
management, encryption (of the data, of the storage media, and/or
of network traffic on the system), physical isolation, network
isolation, geographic placement, and the like. A storage location
plan 12588 or profile may account for or specify a location for
storage, such as a geolocation, a network location (e.g., at the
edge, on a given server, or within a given cloud platform or
platforms), or a location on a device, such as a location on a data
collector, a location on a handheld device (such as a smart phone,
tablet, or personal computer of an operator within an environment),
a location within or across a group of devices (such as a mesh, a
peer-to-peer group, a ring, a hub-and-spoke group, a set of
parallel devices, a swarm of devices (such as a swarm of
collectors), or the like), a location in an industrial environment
(such as or within an storage element of an instrumentation system
of or for a machine, a location on an information technology system
for the environment, or the like), or a dedicated storage system,
such as a disk, dongle, USB device, or the like. A storage backup
plan 12590 or profile may account for or specify a plan for backup
or redundancy of stored data, such as indicating redundant
locations and managing any or all of the above factors for a backup
storage location. In certain embodiments, the storage security plan
12586 and/or storage backup plan 12590 may specify parameters such
as data retention, long-term storage plans (e.g., migrate the
stored data to a different storage media after a period of time
and/or after certain operations in the system are performed on the
data), physical risk management of the data and/or storage media
(e.g., provision of the data in multiple geographic regions having
distinct physical risk parameters, movement of the data when a
storage location experiences a physical risk, refreshing the data
according to a predicted life cycle of a long-term storage media,
etc.).
[1637] The example controller 12512 further includes a sensor data
storage implementation circuit 12526 that stores at least a portion
of the number of sensor data values in response to the data storage
profile 12532. An example controller 12512 includes the data
storage profile 12532 having a storage location definition 12534
corresponding to at least one of the number of sensor data values
12542, including at least one location such as: a sensor storage
location (e.g., data stored for a period of time on the sensor,
and/or on a portable device for a user 12518 in proximity to the
industrial system 12502 where the portable device is adapted by the
system as a sensor), a sensor communication device storage location
(e.g., a data controller 12508, MUX device, smart sensor in
communication with other sensors, and/or on a portable device for a
user 12518 in proximity to the industrial system 12502 or a network
of the industrial system 12502 where the portable device is adapted
by the system as a communication device to transfer sensor data
between components in the system, etc.), a regional network storage
location (e.g., on a plant computer 12510 and/or controller 12512),
and/or a global network storage location (e.g., on a cloud
computing device 12514).
[1638] An example controller 12512 includes the data storage
profile 12532 including a storage time definition 12536
corresponding to at least one of the number of sensor data values
12542, including at least one time value such as: a time domain
description over which the corresponding at least one of the number
of sensor data values is to be stored (e.g., times and locations
for the data, which may include relative time to some aspect such
as the time of data sampling, a process stage start or stop time,
etc., or an absolute time such as midnight, Saturday, the first of
the month, etc.); a time domain storage trajectory including a
number of time values corresponding to a number of storage
locations over which the corresponding at least one of the number
of sensor data values is to be stored (e.g., the flow of the sensor
data through the system across a number of devices, with the time
for each storage transfer including a relative or absolute time
description); a process description value over which the
corresponding at least one of the number of sensor data values is
to be stored (e.g., including a process description and the planned
storage location for data values during the described process
portion; the process description can include stages of a process,
and identification of which process is related to the storage plan,
and the like); and/or a process description trajectory including a
number of process stages corresponding to a number of storage
locations over which the corresponding at least one of the number
of sensor data values is to be stored (e.g., the flow of the sensor
data through the system across a number of devices, with process
stage and/or process identification for each storage transfer).
[1639] An example controller 12512 includes the data storage
profile 12532 including a data resolution description 12540
corresponding to at least one of the number of sensor data values
12544, where the data resolution description 12540 includes a value
such as: a detection density value corresponding to the at least
one of the number of sensor data values (e.g., detection density
may be time sampling resolution, spatial sampling resolution,
precision of the sampled data, and/or a processing operation to be
applied that may affect the available resolution, such as filtering
and/or lossy compression of the data); a detection density value
corresponding to a more than one of the number of the sensor data
values (e.g., a group of sensors having similar detection density
values, a secondary data value determined from a group of sensors
having a specified detection density value, etc.); a detection
density trajectory including a number of detection density values
of the at least one of the number of sensor data values, each of
the number of detection density values corresponding to a time
value (e.g., any of the detection density concepts combined with
any of the time domain concepts); a detection density trajectory
including a number of detection density values of the at least one
of the number of sensor data values, each of the number of
detection density values corresponding to a process stage value
(e.g., any of the detection density concepts combined with any of
the process description or stage concepts); and/or a detection
density trajectory comprising a number of detection density values
of the at least one of the number of sensor data values, each of
the number of detection density values corresponding to a storage
location value (e.g., detection density can be varied according to
the device storing the data).
[1640] An example sensor data storage profile circuit 12524 further
updates the data storage profile 12532 after the operations of the
sensor data storage implementation circuit 12526, where the sensor
data storage implementation circuit 12526 further stores the
portion of the number of sensor data values 12544 in response to
the updated data storage profile 12532. For example, during
operations of a system at a first point in time, the sensor data
storage implementation circuit 12526 utilizes a currently existing
data storage profile sensor data storage implementation circuit
12526, which may be based on initial estimates of the system
performance, desired data from an operator of the system, and/or
from a previous operation of the sensor data storage profile
circuit 12524. During operations of the system, the sensor data
storage implementation circuit 12526 stores data according to the
data storage profile 12532, and the sensor data storage profile
circuit 12524 determines parameters for the data storage profile
12532 which may result in improved performance of the system. An
example sensor data storage profile circuit 12524 tests various
parameters for the data storage profile 12532, for example
utilizing a machine learning optimization routine, and upon
determining that an improved data storage profile 12532 is
available, the sensor data storage profile circuit 12524 provides
the updated data storage profile 12532 which is utilized by the
sensor data storage implementation circuit 12526. In certain
embodiments, the sensor data storage profile circuit 12524 may
perform various operations such as supplying an intermediate data
storage profile 12532 which is utilized by the sensor data storage
implementation circuit 12526 to produce real-world results, applies
modeling to the system (either first principles modeling based on
system characteristics, a model utilizing actual operating data for
the system, a model utilizing actual operating data for an offset
system, and/or combinations of these) to determine what an outcome
of a given data storage profile 12532 will be or would have been
(including, for example, taking extra sensor data beyond what is
utilized to support a process operated by the system), and/or
applying randomized changes to the data storage profile 12532 to
ensure that an optimization routine does not settle into a local
optimum or non-optimal condition.
[1641] An example sensor data storage profile circuit 12524 further
updates the data storage profile 12532 in response to external data
12544 and/or cloud-based data 12538, including data such as: an
enhanced data request value (e.g., an operator, model, optimization
routine, and/or other process requests enhanced data resolution for
one or more parameters); a process success value (e.g., indicating
that current storage practice provides for sufficient data
availability and/or system performance; and/or that current storage
practice may be over-capable, and one or more changes to reduce
system utilization may be available); a process failure value
(e.g., indicating that current storage practices may not provide
for sufficient data availability and/or system performance, which
may include additional operations or alerts to an operator to
determine whether the data transmission and/or availability
contributed to the process failure); a component service value
(e.g., an operation to adjust the data storage to ensure higher
resolution data is available to improve a learning algorithm
predicting future service events, and/or to determine which factors
may have contributed to premature service); a component maintenance
value (e.g., an operation to adjust the data storage to ensure
higher resolution data is available to improve a learning algorithm
predicting future maintenance events, and/or to determine which
factors may have contributed to premature maintenance); a network
description value (e.g., a change in the network, for example by
identification of devices, determination of protocols, and/or as
entered by a user or operator, where the network change results in
a capability change and potentially a distinct optimal storage plan
for sensor data); a process feedback value (e.g., one or more
process conditions detected); a network feedback value (e.g., one
or more network changes as determined by actual operations of the
network--e.g., a loss or reduction in communication of one or more
devices, a network communication volume change, a transmission
noise value change on the network, etc.); a sensor feedback value
(e.g., metadata such as a sensor fault, capability change; and/or
based on the detected data from the system, for example an
anomalous reading, rate of change, or off-nominal condition
indicating that enhanced or reduced resolution, sampling time, etc.
should change the storage plan); and/or a second data storage
profile, where the second data storage profile was generated for an
offset system.
[1642] An example storage planning circuit 12528 determines a data
configuration plan 12546 and updates the data storage profile 12532
in response to the data configuration plan 12546, where the sensor
data storage implementation circuit 12526 further stores at least a
portion of the number of sensor data values in response to the
updated data storage profile 12532. An example data configuration
plan 12546 includes a value such as: a data storage structure value
(e.g., a data type, such as integer, string, a comma delimited
file, how many bits are committed to the values, etc.); a data
compression value (e.g., whether to compress data, a compression
model to use, and/or whether segments of data can be replaced with
summary information, polynomial or other curve fit summarizations,
etc.); a data write strategy value (e.g., whether to store values
in a distributed manner or on a single device, which network
communication and/or operating system protocols to utilize); a data
hierarchy value (e.g., which data is favored over other data where
storage constraints and/or communication constraints will limit the
stored data--the limits may be temporal, such as data will not be
in the intended location at the intended time, or permanent, such
as some data will need to be compressed in a lossy manner, and/or
lost); an enhanced access value determined for the data (e.g., the
data is of a type for reports, searching, modeling access, and/or
otherwise tagged, where enhanced access includes where the data is
stored for scope of availability, indexing of data, summarization
of data, topical reports of data, which may be stored in addition
to the raw or processed sensor data); and/or an instruction value
corresponding to the data (e.g., a placeholder indicating where
data can be located, an interface to access the data, metadata
indicating units, precision, time frames, processes in operation,
faults present, outcomes, etc.).
[1643] It can be seen that the provision of control over data flow
and storage through the system allows for improvement generally,
and movement toward optimization over time, of data management
throughout the system. Accordingly, more data of a higher
resolution can be accumulated, and in a more readily accessible
manner, than previously known systems with fixed or manually
configurable data storage and flow for a given utilization of
resources such as storage space, communication bandwidth, power
consumption, and/or processor execution cycles. Additionally, the
system can respond to process variations that affect the optimal or
beneficial parameters for controlling data flow and storage. One of
skill in the art, having the benefit of the disclosures herein,
will recognize that combinations of control of data storage schemes
with data type control and knowledge about process operations for a
system create powerful combinations in certain contemplated
embodiments. For example, data of a higher resolution can be
maintained for a longer period and made available if a need for the
data arises, without incurring the full cost of storing the data
permanently and/or communicating the data throughout every layer of
the system.
[1644] In an embodiment, in an underground mining inspection
system, certain detailed data regarding toxic gas concentrations,
temperatures, noise, etc. may need to be captured and stored for
regulatory purposes, but for ongoing operational purposes, perhaps
only a single data point regarding one or more toxic gases is
needed periodically. In this embodiment, the data storage profile
for the system may indicate that only certain sensor data aligned
with regulatory needs be stored in a certain manner that is long
term and optionally only available as needed, while other sensor
data required operationally be stored in a more accessible
manner.
[1645] In another embodiment involving automotive brakes for fleet
vehicles, data regarding brake use and performance may be acquired
at high resolution and stored in a first data storage that is not
transmitted throughout the network, while lower resolution data are
transmitted periodically and/or in near real time to a fleet
control and maintenance application. Should the application or
other user require higher resolution data, it may be accessed from
the first data storage.
[1646] In a further embodiment of manufacturing body and frame
components of trucks and cars, certain detailed data regarding
paint color, surface curvature, and other quality control measures
may be captured and stored at high resolution, but for ongoing
operational purposes, only low resolution data regarding throughput
are transmitted. In this embodiment, the data storage profile for
the system may indicate that only certain sensor data aligned with
quality control needs be stored in a certain manner that is long
term and optionally only available as needed, while other sensor
data required operationally be stored in a more accessible
manner.
[1647] In another example, data types, resolution, and the like can
be configured and changed as the data flows through the system,
according to values that are beneficial for the individual
components handling the data, according to the utilized networking
resources for the data, and/or according to accompanying data
(e.g., a model, virtual sensor, and/or sensor fusion operation)
where higher capability data would not improve the precision of the
process utilizing the accompanying data.
[1648] In an embodiment, in rail condition monitoring systems, as
rail condition data are acquired, each component of the system may
require different resolutions of the same data. Continuing with
this example, as real-time rail traffic data are acquired, these
data may be stored and/or transmitted at low resolution in order to
quickly disseminate the data throughout the system, while
utilization and load data may be stored and utilized at higher
resolution to track rail use fees and need for rail maintenance at
a more granular level.
[1649] In another embodiment of a hydraulic pump operating in a
tractor, as the tractor is in the field and does not have access to
a network, data from on-board sensors may be acquired and stored in
a local manner on the tractor at low resolution, but when the
tractor regains access, data may be acquired and transmitted at
high resolution.
[1650] In yet another embodiment of an actuator in a robotic
handling unit in an automotive plant, data regarding the actuator
may flow into multiple downstream systems, such as a production
tracking system that utilizes the actuator data alone and an energy
efficiency tracking system that utilizes the data in a sensor
fusion with data from environmental sensors. Resolution of the
actuator data may be configured differently as it is transmitted to
each of these systems for their disparate uses.
[1651] In still another embodiment of a generator in a mine, data
may be acquired regarding the performance of the generator, carbon
monoxide levels near the generator and a cost for running the
generator. Each component of a control system overseeing the mine
may require different resolutions of the same data. Continuing with
this example, as carbon monoxide data are acquired, these data may
be stored and/or transmitted at low resolution in order to quickly
disseminate the data throughout the system in order to properly
alert workers. Performance and cost data may be stored and utilized
at higher resolution to track economic efficiency and lifetime
maintenance needs.
[1652] In an additional embodiment, sensors on a truck's wheel end
may monitor lubrication, noise (e.g., grinding, vibration) and
temperature. While in the field, sensor data may be transmitted
remotely at low resolution for remote monitoring, but when within a
threshold distance from a fleet maintenance facility, data may be
transmitted at high resolution.
[1653] In another example, accompanying information for the data
allows for efficient downstream processing (e.g., by a downstream
device or process accessing the data) including unpackaging the
data, readily determining where related higher capability data may
be present in the system, and/or streamlining operations utilizing
the data (e.g., reporting, modeling, alerting, and/or performing a
sensor fusion or other system analysis). An embodiment includes
storing high capability (e.g., high-sampling rate, high precision,
indexed, etc.) in a first storage device in the system (e.g., close
to the sensors in the network layer to preserve network
communication resources) and sending lower capability data up the
network layers (e.g., to a cloud-computing device), where the lower
capability data includes accompanying information to access the
stored high capability data, including accompanying data that may
be accessible to a user (e.g., a header, message box, or other
organically interfaceable accompanying data) and/or accessible to
an automated process (e.g., structured data, XML, populated fields,
or the like) where the process can utilize the accompanying data to
automatically request, retrieve, or access the high capability
data. In certain embodiments, accompanying data may further include
information about the content, precision, sampling time,
calibrations (e.g., de-bouncing, filtering, or other processing
applied) such that an accessing component or user can determine
without retrieving the high capability data whether such data will
meet the desired parameters.
[1654] In an embodiment, vibration noise from vibration sensors
attached to vibrators on an assembly line may be stored locally in
a high resolution format while a low resolution version of the same
data with accompanying information regarding the availability of
ambient and local noise data for a sensor fusion may be transmitted
to a cloud-based server. If a resident process on the server
requires the high resolution data, such as a machine learning
process, the server may retrieve the data at that time.
[1655] In another embodiment of an airplane engine, performance
data aggregated from a plurality of sensors may be transmitted
while in flight along with accompanying information to a remote
site. The accompanying information, such as a header with metadata
relating to historical plane information, may allow the remote site
to efficiently analyze the performance data in the context of the
historical data without having to access additional databases.
[1656] In a further embodiment of a coal crusher in a power
generation facility, data accompanying low quality sensor data
regarding the size of coal exiting the crusher may include
information about the precision in the size measurement such that a
technician can determine if the higher resolution data are needed
to confirm a determination that the crusher needs to come offline
for maintenance.
[1657] In yet a further embodiment of a drilling machine or
production platform employed in oil and gas production, high
capability data may be acquired and stored locally regarding
parameters of the drill's and platform's operation, but only low
capability data are transmitted off-site to conserve bandwidth.
Along with the low capability data, accompanying information may
include instructions on how an automated off-site process can
automatically access the high capability data in the event that it
is required.
[1658] In still a further embodiment, temperature sensors on a pump
employed in oil & gas production or mining may be stored
locally in a high resolution format while a low resolution version
of the same data with accompanying information regarding the
availability of noise and energy use data for a sensor fusion may
be transmitted to a cloud-based server. If a resident process on
the server requires the high resolution data, such as a machine
learning process, the server may retrieve the data at that
time.
[1659] In another embodiment of a gearbox in an automatic robotic
handling unit or an agricultural setting, performance data
aggregated from a plurality of sensors may be transmitted while in
use along with accompanying information to a remote site. The
accompanying information, such as a header with metadata relating
to historical gearbox information, may allow the remote site to
efficiently analyze the performance data in the context of the
historical data without having to access additional databases.
[1660] In a further embodiment of a ventilation system in a mine,
data accompanying low quality sensor data regarding the size of
particulates in the air may include information about the precision
in the size measurement such that a technician can determine if the
higher resolution data are needed to confirm a determination that
the ventilation system requires maintenance.
[1661] In yet a further embodiment of a rolling bearing employed in
agriculture, high capability data may be acquired and stored
locally regarding parameters of the rolling bearing's operation,
but only low capability data are transmitted off-site to conserve
bandwidth. Along with the low capability data, accompanying
information may include instructions on how an automated off-site
process can automatically access the high capability data in the
event that it is required.
[1662] In a further embodiment of a stamp mill in a mine, data
accompanying low quality sensor data regarding the size of mineral
deposits exiting the stamp mill may include information about the
precision in the size measurement such that a technician can
determine if the higher resolution data are needed to confirm a
determination that the stamp mill requires a change in an operation
parameter.
[1663] Referencing FIG. 176, an example storage time definition
12536 is depicted. The example storage time definition 12536
depicts a number of storage locations 12556 corresponding to a
number of time values 12558. It is understood that any values such
as storage types, storage media, storage access, storage protocols,
storage writing values, storage security, and/or storage backup
values, may be included in the storage time definition 12536.
Additionally or alternatively, an example storage time definition
12536 may include process operations, events, and/or other values
in addition to or as an alternative to time values 12558. The
example storage time definition 12536 depicts movement of related
sensor data to a first storage location 12550 over a first time
interval, to a second storage location 12552 over a second time
internal, and to a third storage location 12554 over a third time
interval. The storage location values 12550, 12552, 12554 are
depicted as an integral selection corresponding to planned storage
locations, but additionally or alternatively the values may be
continuous or discrete, but not necessarily integral values. For
example, a storage location value 12550 of "1" may be associated
with a first storage location, and a storage location value 12550
of "2" may be associated with a second storage location, where a
value between "1" and "2" has an understood meaning--such as a
prioritization to move the data (e.g., a "1.1" indicates that the
data should be moved from "2" to "1" with a relatively high
priority compared to a "1.4"), a percentage of the data to be moved
(e.g., to control network utilization, memory utilization, or the
like during a transfer operation), and/or a preference for a
storage location with alternative options (e.g., to allow for
directing storage location, and inclusion in a cost function such
that storage location can be balanced with other constraints in the
system). Additionally or alternatively, the storage time definition
12536 can include additional dimensions (e.g., changing protocols,
media, security plans, etc.) and/or can include multiple options
for the storage plan (e.g., providing a weighted value between 2,
3, 4, or more storage locations, protocols, media, etc. in a
triangulated or multiple-dimension definition space).
[1664] Referencing FIG. 177 an example data resolution description
12540 is depicted. The example data resolution description 12540
depicts a number of data resolution values 12562 corresponding to a
number of time values 12564. It is understood that any values such
as storage types, storage media, storage access, storage protocols,
storage writing values, storage security, and/or storage backup
values, may be included in the data resolution description 12540.
Additionally or alternatively, an example data resolution
description 12540 may include process operations, events, and/or
other values in addition to or as an alternative to time values
12558. The example data resolution description 12540 depicts
changes in the resolution of stored related sensor data resolution
values 12560 over time intervals, for example operating at a low
resolution initially, stepping up to a higher resolution (e.g.,
corresponding to a process start time), to a high resolution value
(e.g., during a process time where the process is significantly
improved by high resolution of the related sensor data), and to a
low resolution value (e.g., after a completion of the process). The
example depicts a higher resolution before the process starts than
after the process ends as an illustrative example, but the data
resolution description 12540 may include any data resolution
trajectory. The data resolution values 12560 are depicted as
integral selections corresponding to planned data resolutions, but
additionally or alternatively the values may be continuous or
discrete, but not necessarily integral values. For example, data
resolution values 12560 of "1" may be associated with a first data
resolution (e.g., a specific sampling time, byte resolution, etc.),
and a data resolution values 12560 of "2" may be associated with a
second data resolution, where a value between "1" and "2" has an
understood meaning--such as a prioritization to sample at the
defined resolution (e.g., a "1.1" indicates the data should be
taken at a sampling rate corresponding to "1" with a relatively
high priority compared to a "1.3", and/or at a sampling rate 10% of
the way between the rate between "1" and "2"), and/or a preference
for a data resolution with alternative options (e.g., to allow for
sensor or network limitations, available sensor communication
devices such as a data controller, smart sensor, or portable device
taking the data from the sensor, and/or inclusion in a cost
function such that data resolution can be balanced with other
constraints in the system). Additionally or alternatively, the data
resolution description 12540 can include additional dimensions
(e.g., changing protocols, media, security plans, etc.) and/or can
include multiple options for the data resolution plan (e.g.,
providing a weighted value between 2, 3, 4, or more data resolution
values, protocols, media, etc. in a triangulated or
multiple-dimension definition space).
[1665] An example system 12500 further includes a haptic feedback
circuit 12530 that determines a haptic feedback instruction 12548
in response to at least one of the number of sensor values 12542
and/or the data storage profile 12532, and a haptic feedback device
12516 responsive to the haptic feedback instruction 12548. Example
and non-limiting haptic feedback instructions 12548 include an
instruction such as: a vibration command; a temperature command; a
sound command; an electrical command; and/or a light command
Example and non-limiting operations of the haptic feedback circuit
12530 include feedback that data is stored or being stored on the
haptic feedback device 12516 and/or on a portable device associated
with the user 12518 in communication with the haptic feedback
device 12516 (e.g., user 12518 traverses through the system 12500
with a smart phone, which the system 12500 utilizes to store sensor
data, and provides a haptic feedback instructions 12548 to notify
the user 12518 that the smart phone is currently being utilized by
the system 12500, for example allowing the user 12518 to remain in
communication with the sensor, data controller, or other
transmitting device, and/or allowing the user to actively cancel or
enable the data transfer). Additionally or alternatively, the
haptic feedback device 12516 may be the smart phone (e.g.,
utilizing vibration, sound, light, or other haptic aspects of the
smart phone), and/or the haptic feedback device 12516 may include
data storage and/or communication capabilities.
[1666] In certain embodiments, the haptic feedback circuit 12530
provides a haptic feedback instruction 12548 as an alert or
notification to the user 12518, for example to alert or notify the
user 12518 that a process has commenced or is about to start, that
an off-nominal operation is detected or predicted, that a component
of the system requires or is predicted to require maintenance, that
an aspect of the system is in a condition that the user 12518 may
want to be aware of (e.g., a component is still powered, has high
potential energy of any type, is at a high pressure, and/or is at a
high temperature where the user 12518 may be in proximity to the
component), that a data storage related aspect of the system is in
a noteworthy condition (e.g., a data storage component of the
system is at capacity, out of communication, is in a fault
condition, has lost contact with a sensor, etc.), to request a
response from the user 12518 (e.g., an approval to start a process,
data transfer, process rate change, clear a fault, etc.) In certain
embodiments, the haptic feedback circuit 12530 configures the
haptic feedback instruction 12548 to provide an intuitive feedback
to the user 12518. For example, an alert value may provide a more
rapid, urgent, and/or intermittent vibration mode relative to an
informational notification; a temperature based alert or
notification may utilize a temperature based haptic feedback (e.g.,
an overtemperature vessel notification may provide a warm or cold
haptic feedback) and/or flashing a color that is associated with
the temperature (e.g., flashing red for an overtemperature or blue
for an under-temperature); an electrically based notification may
provide an electrically associated haptic feedback (e.g., a sound
associated with electricity such as a buzzing or sparking sound, or
even a mild electrical feedback such as when a user is opening a
panel for a component that is still powered); providing a vibration
feedback for a bearing, motor, or other rotating or vibrating
component that is operating off-nominally; and/or providing a
requested feedback to the user based upon sensed data (e.g.,
transmitting a vibration profile to the haptic feedback device that
is analogous to the detected vibration in a requested component for
example allowing an expert user to diagnose the component without
physical contact; providing a haptic feedback for a requested
component for example if the user is double checking a
lockout/tagout operation before entering a component, opening a
panel, and/or entering a potentially hazardous area). The provided
examples for operations of the haptic feedback circuit 12530 are
non-limiting illustrations.
[1667] Referencing FIG. 178, an example apparatus for data
collection in an industrial environment 12566 includes a controller
12512 a sensor communication circuit 12522 that interprets a number
of sensor data values 12542, a sensor data storage profile circuit
12524 that determines a data storage profile 12532, where the data
storage profile 12532 includes a data storage plan for the number
of sensor data values 12542, and a network coding circuit 12568
that provides a network coding value 12570 in response to the
number of sensor data values 12542 and the data storage profile
12532. The controller 12512 further includes a sensor data storage
implementation circuit 12526 that stores at least a portion of the
number of sensor data values 12542 in response to the data storage
profile 12532 and the network coding value 12570. The network
coding value 12570 includes, without limitation, network encoding
for data transmission, such as packet sizing, distribution,
combinations of sensor data within packets, encoding and decoding
algorithms for network data and communications, and/or any other
aspects of controlling network communications throughout the
system. In certain embodiments, the network coding value 12570
includes a linear network coding algorithm, a random linear network
coding algorithm, and/or a convolutional code. Additionally or
alternatively, the network coding circuit 12568 provides scheduling
and/or synchronization for network communication devices of the
system, and can include separate scheduling and/or synchronization
for separate networks in the system. The network coding circuit
12568 schedules the network coding value 12570 throughout the
system according to the data volumes, transfer rates, and network
utilization, and alternatively or additionally performs a
self-learning and/or machine learning operation to improve or
optimize network coding. For example, a sensor having a single
low-volume data transfer to a data controller may utilize TCP/IP
packet communication to the data controller without linear network
coding, while higher volume aggregated data transfer from the data
controller to another system component (e.g., the controller 12532)
may utilize linear network coding. The example network coding
circuit 12568 adjusts the network coding value 12570 in real time
for the components in the system to optimize or improve transfer
rates, power utilization, errors and lost packets, and/or any other
desired parameters. For example, a given component may have
resulting low transfer rates but a large available memory, while a
downstream component has a lower available memory (potentially
relative to the data storage expectation for that component), and
accordingly a complex network coding value 12570 for the given
component may not result in improved throughput of data throughout
the system, while a network coding value 12570 enhancing throughput
for the downstream component may justify the processing overhead
for a more complex network coding value 12570.
[1668] An example system includes the network coding circuit 12568
further determining a network definition value 12572, and providing
the network coding value 12570 further in response to the network
definition value 12572. Example network definition values 12572
include values such as: a network feedback value (e.g., transfer
rates, up time, synchronization availability, etc.); a network
condition value (e.g., presence of noise, transmission/receiver
capability, drop-outs, etc.); a network topology value (e.g., the
communication flow and connectivity of devices; operating systems,
protocols, and storage types of devices; available computing
resources on devices; the location and function of devices in the
system); an intermittently available network device value (e.g., a
known or observed availability for the device over time or process
stage; predicted availability of the device; prediction of known
noise factors for the device, such as process operations that
reduce device availability); and/or a network cost description
value (e.g., resource utilization of the device, including relative
cost or impact of processing, memory, and/or communication
resources; power utilization and cost of power consumption for
devices; available power for the device and a cost description for
externalities related to consuming the power--such as for a battery
where the power itself may not be expensive but the power in the
specific location has a cost associated with replacement, including
availability or access to the device during operations).
[1669] An example system includes the network coding circuit 12568
further providing the network coding value 12570 such that the
sensor data storage implementation circuit stores a first portion
of the number of sensor data values 12542 utilizing a first network
coding value 12570, and a second portion of the number of sensor
data values 12542 utilizing a second network coding value 12570
(e.g., the network coding values 12570 can vary with the data being
transmitted, the transmitting device, and/or over time or process
stage). Example and non-limiting network coding values include: a
network type selection (e.g., public, private, wireless, wired,
intranet, external, internet, cellular, etc.), a network selection
(e.g., which one or more of an available number of networks will be
utilized), a network coding selection (e.g., packet definitions,
encoding techniques, linear, randomized linear, convolution,
triangulated, etc.), a network timing selection (e.g.,
synchronization and sequencing of data transmissions between
devices), a network feature selection (e.g., turning on or off
network support devices or repeaters; enabling, disabling, or
adjusting security selections; increasing or decreasing a power of
a device, etc.), a network protocol selection (e.g., TCP/IP, FTP,
Wi-Fi, Bluetooth, Ethernet, and/or routing protocols); a packet
size selection (including header and/or parity information); and/or
a packet ordering selection (e.g., determining how to transmit the
various sensor information that may be on a device, and/or
determining the packet to data value correspondence). An example
network coding circuit 12568 further adjusts the network coding
value 12570 to provide an intermediate network coding value (e.g.,
as a test coding value on the system, and/or as a modeled coding
value being run off-line), to compare a performance indicator 12574
corresponding to each of the network coding value 12570 and the
intermediate network coding value, and to provide an updated
network coding value (e.g., as the network coding value 12570) in
response to the comparison of the performance indicators 12574.
[1670] An example system includes an industrial system having a
number of components, and a number of sensors each operatively
coupled to at least one of the number of components. The number of
sensors provide a number of sensor values, and the system further
includes a number of organizing structures such as a controller, a
data collector, a plant computer, a cloud-based server and/or
global computing device, and/or a network layer, where the
organizing structures are configured for self-organizing storage of
at least a portion of the number of sensor values. For example,
operations of the controller 12512 provide for storage and
distribution of sensor data values to reduce consumption of
resources (processor, network, and/or memory) for storing sensor
data. The self-organizing operations include management of the
stored sensor data over time, including providing sensor
information to system components in time to complete operations
therefore (e.g., control, improvement, modeling, and/or machine
learning for process operations of the system). Additionally, data
security, including long-term security due to storage media,
geographic, and/or unauthorized access, is considered throughout
the data storage life cycle. An example system further includes the
organizing structures providing enhanced resolution of the number
of sensor values in response to at least one of an enhanced data
request value or an alert value corresponding to the industrial
system. The system provides enhanced resolution by controlling the
storage processes to address system impact, including keeping lower
resolution, summary, or other accessibility data available, and
storing higher resolution data in a lower resource utilization
manner which is available upon request and/or at a time appropriate
to system operations. Example enhanced resolution includes: an
enhanced spatial resolution, an enhanced time domain resolution, a
greater number of the number of sensor values than a standard
resolution of the number of sensor values, and/or a greater
precision of at least one of the number of sensor values than a
standard resolution of the number of sensor values. An example
system further includes a network layer, where the organizing
structures are configured for self-organizing network coding for
communication of the number of sensor values on the network layer.
An example system further includes a haptic feedback device of a
user in proximity to at least one of the industrial system or the
network layer, and where the organizing structures are configured
for providing haptic feedback to the haptic feedback device, and/or
for configuring the haptic feedback to provide an intuitive alert
to the user.
[1671] In embodiments, a system for data collection in an
industrial environment may comprise: a sensor communication circuit
structured to interpret a plurality of sensor data values; a sensor
data storage profile circuit structured to determine a data storage
profile, the data storage profile comprising a data storage plan
for the plurality of sensor data values; and a sensor data storage
implementation circuit structured to store at least a portion of
the plurality of sensor data values in response to the data storage
profile. In embodiments, the data storage profile may include a
storage location definition corresponding to at least one of the
plurality of sensor data values, the storage location definition
comprising at least one location selected from the locations
consisting of: a sensor storage location, a sensor communication
device storage location, a regional network storage location, and a
global network storage location. The data storage profile may
include a storage time definition corresponding to at least one of
the plurality of sensor data values, the storage time definition
comprising at least one time value selected from the time values
consisting of: a time domain description over which the
corresponding at least one of the plurality of sensor data values
is to be stored; a time domain storage trajectory comprising a
plurality of time values corresponding to a plurality of storage
locations over which the corresponding at least one of the
plurality of sensor data values is to be stored; a process
description value over which the corresponding at least one of the
plurality of sensor data values is to be stored; and a process
description trajectory comprising a plurality of process stages
corresponding to a plurality of storage locations over which the
corresponding at least one of the plurality of sensor data values
is to be stored. The data storage profile may include a data
resolution description corresponding to at least one of the
plurality of sensor data values, wherein the data resolution
description comprises at least one of: a detection density value
corresponding to the at least one of the plurality of sensor data
values; a detection density value corresponding to a plurality of
the at least one of the plurality of the sensor data values; a
detection density trajectory comprising a plurality of detection
density values of the at least one of the plurality of sensor data
values, each of the plurality of detection density values
corresponding to a time value; a detection density trajectory
comprising a plurality of detection density values of the at least
one of the plurality of sensor data values, each of the plurality
of detection density values corresponding to a process stage value;
and a detection density trajectory comprising a plurality of
detection density values of the at least one of the plurality of
sensor data values, each of the plurality of detection density
values corresponding to a storage location value. The sensor data
storage profile circuit may be further structured to update the
data storage profile after the operations of the sensor data
storage implementation circuit, and wherein the sensor data storage
implementation circuit is further structured to store the portion
of the plurality of sensor data values in response to the updated
data storage profile. The sensor data storage profile circuit may
be further structured to update the data storage profile in
response to external data, the external data comprising at least
one data value selected from the data values consisting of: an
enhanced data request value; a process success value; a process
failure value; a component service value; a component maintenance
value; a network description value; a process feedback value; a
network feedback value; a sensor feedback value; and a second data
storage profile, the second data storage profile generated for an
offset system. A storage planning circuit may be structured to
determine a data configuration plan, to update the data storage
profile in response to the data configuration plan, and wherein the
sensor data storage implementation circuit is further structured to
store the at least a portion of the plurality of sensor data values
in response to the updated data storage profile. The data
configuration plan may include at least one value selected from the
values consisting of: a data storage structure value; a data
compression value; a data write strategy value; a data hierarchy
value; an enhanced access value determined for the data; and an
instruction value corresponding to the data. A haptic feedback
circuit may be structured to determine a haptic feedback
instruction in response to at least one of the plurality of sensor
values or the data storage profile; and a haptic feedback device
responsive to the haptic feedback instruction. The haptic feedback
instruction may include at least one instruction selected from the
instructions consisting of: a vibration command; a temperature
command; a sound command; an electrical command; and a light
command. The data storage plan may be generated by a rule-based
expert system utilizing feedback, wherein the feedback relates to
one or more of an aspect of the industrial environment or the
plurality of sensor data values. The data storage plan may be
generated by a model-based expert system utilizing feedback,
wherein the feedback relates to one or more of an aspect of the
industrial environment or the plurality of sensor data values. The
data storage plan may be generated by an iterative expert system
utilizing feedback, wherein the feedback relates to one or more of
an aspect of the industrial environment or the plurality of sensor
data values. The data storage plan may be generated by a deep
learning machine system utilizing feedback, wherein the feedback
relates to one or more of an aspect of the industrial environment
or the plurality of sensor data values. The data storage plan may
be based on one or more an underlying physical media type of the
storage, a type of device or system on which storage resides, and a
mechanism by which storage can be accessed for reading or writing
data. The underlying physical media may be one of a tape media, a
hard disk drive media, a flash memory media, a non-volatile memory,
an optical media, and a one-time programmable memory. The data
storage plan may account for or specifies a parameter relating to
the underlying physical media comprising one or more of a storage
duration, a power usage, a reliability, a redundancy, a thermal
performance factor, a robustness to environmental conditions, an
input/output speed and capability, a writing speed, a reading
speed, a data file organization, an operating system, a read-write
life cycle, a data error rate, and a data compression aspect
related to or inherent to the underlying physical media or a media
controller. The data storage plan may include one or more of a
storage type plan, a storage media plan, a storage access plan, a
storage protocol plan, a storage writing protocol plan, a storage
security plan, a storage location plan, and a storage backup
plan.
[1672] In embodiments, a system for data collection in an
industrial environment may comprise: a sensor communication circuit
structured to interpret a plurality of sensor data values; a sensor
data storage profile circuit structured to determine a data storage
profile, the data storage profile comprising a data storage plan
for the plurality of sensor data values; a network coding circuit
structured to provide a network coding value in response to the
plurality of sensor data values and the data storage profile; and a
sensor data storage implementation circuit structured to store at
least a portion of the plurality of sensor data values in response
to the data storage profile and the network coding value. The
network coding circuit may be structured to determine a network
definition value, and to provide the network coding value further
in response to the network definition value, wherein the network
definition value comprises at least one value selected from the
values consisting of: a network feedback value; a network condition
value; a network topology value; an intermittently available
network device value; and a network cost description value. The
network coding circuit may be structured to provide the network
coding value such that the sensor data storage implementation
circuit stores a first portion of the plurality of sensor data
values utilizing a first network coding value, and a second portion
of the plurality of sensor data values utilizing a second network
coding value. The network coding value may include at least one of
the values selected from the values consisting of: a network type
selection, a network selection, a network coding selection, a
network timing selection, a network feature selection, a network
protocol selection, a packet size selection, and a packet ordering
selection. The network coding circuit may be further structured to
adjust the network coding value to provide an intermediate network
coding value, to compare a performance indicator corresponding to
each of the network coding value and the intermediate network
coding value, and to provide an updated network coding value in
response to the comparison of the performance indicators.
[1673] In embodiments, a system may comprise: an industrial system
comprising a plurality of components, and a plurality of sensors
each operatively coupled to at least one of the plurality of
components; the plurality of sensors providing a plurality of
sensor values; and a means for self-organizing storage of at least
a portion of the plurality of sensor values. In embodiments, a
means may be provided for enhancing resolution of the plurality of
sensor values in response to at least one of an enhanced data
request value or an alert value corresponding to the industrial
system; and wherein the enhanced resolution comprises at least one
of an enhanced spatial resolution, an enhanced time domain
resolution, a greater number of the plurality of sensor values than
a standard resolution of the plurality of sensor values, and a
greater precision of at least one of the plurality of sensor values
than the standard resolution of the plurality of sensor values. The
system may include a network layer, and a means for self-organizing
network coding for communication of the plurality of sensor values
on the network layer. The system may include a means for providing
haptic feedback to a haptic feedback device of a user in proximity
to at least one of the industrial system or the network layer. The
system may include a means for configuring the haptic feedback to
provide an intuitive alert to the user.
[1674] In embodiments, a system for self-organizing data storage
for data collected from a mine may comprise: a sensor communication
circuit structured to interpret a plurality of sensor data values;
a sensor data storage profile circuit structured to determine a
data storage profile, the data storage profile comprising a data
storage plan for the plurality of sensor data values; and a sensor
data storage implementation circuit structured to store at least a
portion of the plurality of sensor data values in response to the
data storage profile. In embodiments, the system may include a
self-organizing data storage for data collected from an assembly
line, including: a sensor communication circuit structured to
interpret a plurality of sensor data values; a sensor data storage
profile circuit structured to determine a data storage profile, the
data storage profile comprising a data storage plan for the
plurality of sensor data values; and a sensor data storage
implementation circuit structured to store at least a portion of
the plurality of sensor data values in response to the data storage
profile.
[1675] In embodiments, a system for self-organizing data storage
for data collected from an agricultural system may comprise: a
sensor communication circuit structured to interpret a plurality of
sensor data values; a sensor data storage profile circuit
structured to determine a data storage profile, the data storage
profile comprising a data storage plan for the plurality of sensor
data values; and a sensor data storage implementation circuit
structured to store at least a portion of the plurality of sensor
data values in response to the data storage profile.
[1676] In embodiments, a system for self-organizing data storage
for data collected from an automotive robotic handling unit may
comprise: a sensor communication circuit structured to interpret a
plurality of sensor data values; a sensor data storage profile
circuit structured to determine a data storage profile, the data
storage profile comprising a data storage plan for the plurality of
sensor data values; and a sensor data storage implementation
circuit structured to store at least a portion of the plurality of
sensor data values in response to the data storage profile.
[1677] In embodiments, a system for self-organizing data storage
for data collected from an automotive system may comprise: a sensor
communication circuit structured to interpret a plurality of sensor
data values; a sensor data storage profile circuit structured to
determine a data storage profile, the data storage profile
comprising a data storage plan for the plurality of sensor data
values; and a sensor data storage implementation circuit structured
to store at least a portion of the plurality of sensor data values
in response to the data storage profile.
[1678] In embodiments, a system for self-organizing data storage
for data collected from an automotive robotic handling unit may
include: a sensor communication circuit structured to interpret a
plurality of sensor data values; a sensor data storage profile
circuit structured to determine a data storage profile, the data
storage profile comprising a data storage plan for the plurality of
sensor data values; and a sensor data storage implementation
circuit structured to store at least a portion of the plurality of
sensor data values in response to the data storage profile.
[1679] In embodiments, a system for self-organizing data storage
for data collected from an aerospace system may comprise: a sensor
communication circuit structured to interpret a plurality of sensor
data values; a sensor data storage profile circuit structured to
determine a data storage profile, the data storage profile
comprising a data storage plan for the plurality of sensor data
values; and a sensor data storage implementation circuit structured
to store at least a portion of the plurality of sensor data values
in response to the data storage profile.
[1680] In embodiments, a system for self-organizing data storage
for data collected from a railway may include: a sensor
communication circuit structured to interpret a plurality of sensor
data values; a sensor data storage profile circuit structured to
determine a data storage profile, the data storage profile
comprising a data storage plan for the plurality of sensor data
values; and a sensor data storage implementation circuit structured
to store at least a portion of the plurality of sensor data values
in response to the data storage profile.
[1681] In embodiments, a system for self-organizing data storage
for data collected from an oil and gas production system may
comprise: a sensor communication circuit structured to interpret a
plurality of sensor data values; a sensor data storage profile
circuit structured to determine a data storage profile, the data
storage profile comprising a data storage plan for the plurality of
sensor data values; and a sensor data storage implementation
circuit structured to store at least a portion of the plurality of
sensor data values in response to the data storage profile.
[1682] In embodiments, a system for self-organizing data storage
for data collected from a power generation system, the system
comprising: a sensor communication circuit structured to interpret
a plurality of sensor data values; a sensor data storage profile
circuit structured to determine a data storage profile, the data
storage profile comprising a data storage plan for the plurality of
sensor data values; and a sensor data storage implementation
circuit structured to store at least a portion of the plurality of
sensor data values in response to the data storage profile.
[1683] In embodiments, methods and systems are provided for data
collection in or relating to one or more machines deployed in an
industrial environment using self-organized network coding for
network transmission of sensor data in a network. In embodiments,
network coding may be used to specify and manage the manner in
which packets (including streams of packets as noted in various
embodiments disclosed throughout this disclosure and the documents
incorporated by reference) are relayed from a sender (e.g., a data
collector, instrumentation system, computer, or the like in an
industrial environment where data is collected, such as from
sensors or instruments on, in or proximal to industrial machines or
from data storage in the environment) to a receiver (e.g., another
data collector (such as in a swarm or coordinated group),
instrumentation system, computer, storage, or the like in the
industrial environment, or to a remote computer, server, cloud
platform, database, data pool, data marketplace, mobile device
(e.g., mobile phone, personal computer, tablet, or the like), or
other network-connected device of system), such as via one or more
network infrastructure elements (referred to in some cases herein
as nodes), such as access points, switches, routers, servers,
gateways, bridges, connectors, physical interfaces and the like,
using one or more network protocols, such as IP-based protocols,
TCP/IP, UDP, HTTP, Bluetooth, Bluetooth Low Energy, cellular
protocols, LTE, 2G, 3G, 4G, 5G, CDMA, TDSM, packet-based protocols,
streaming protocols, file transfer protocols, broadcast protocols,
multi-cast protocols, unicast protocols, and others. For situations
involving bi-directional communication, any of the above-referenced
devices or systems, or others mentioned throughout this disclosure,
may play the role of sender or receiver, or both. Network coding
may account for availability of networks, including the
availability of multiple alternative networks, such that a
transmission may be delivered across different networks, either
separated into different components or sending the same components
redundantly. Network coding may account for bandwidth and spectrum
availability; for example, a given spectrum may be divided (such as
with sub-dividing spectrum by frequency, by time-division
multiplexing, and other techniques). Networks or components thereof
may be virtualized, such as for purposes of provisioning of network
resources, specification of network coding for a virtualized
network, or the like. Network coding may include a wide variety of
approaches as described in Appendix A, and in connection with
Figures in Appendix A.
[1684] In embodiments, one or more network coding systems or
methods of the present disclosure may use self-organization, such
as to configure network coding parameters for one or more
transmissions over one or more networks using an expert system,
which may comprise a model-based system (such as automatically
selecting network coding parameters or configuration based on one
or more defined or measured parameters relating to a transmission,
such as parameters of the data or content to be transmitted, the
sender, the receiver, the available network infrastructure
components, the conditions of the network infrastructure, the
conditions of the industrial environment, or the like). A model
may, for example, account for parameters relating to file size,
numbers of packets, size of a stream, criticality of a data packet
or stream, value of a packet or stream, cost of transmission,
reliability of a transmission, quality of service, quality of
transmission, quality of user experience, financial yield,
availability of spectrum, input/output speed, storage availability,
storage reliability, and many others as noted throughout this
disclosure. In embodiments, the expert system may comprise a
rule-based system, where one or more rules is executed based on
detection of a condition or parameter, calculation of a variable,
or the like, such as based on any of the above-noted parameters. In
embodiments, the expert system may comprise a machine learning
system, such as a deep learning system, such as based on a neural
network, a self-organizing map, or other artificial intelligence
approach (including any noted throughout this disclosure or the
documents incorporated by reference). A machine learning system in
any of the embodiments of this disclosure may configure one or more
inputs, weights, connections, functions (including functions of
individual neurons or groups of neurons in a neural net) or other
parameters of an artificial intelligence system. Such configuration
may occur with iteration and feedback, optionally involving human
supervision, such as by feeding back various metrics of success or
failure. In the case of network coding, configuration may involve
setting one or more coding parameters for a network coding
specification or plan, such as parameters for selection of a
network, selection one or more nodes, selection of data path,
configuration of timers or timing parameters, configuration of
redundancy parameters, configuration of coding types (including use
of regenerating codes, such as for use of network coding for
distributed storage, such as in peer-to-peer networks, such as a
peer-to-peer network of data collectors, or a storage network for a
distributed ledger, as noted elsewhere in this disclosure),
coefficients for coding (including linear algebraic coefficients),
parameters for random or near-random linear network coding
(including generation of near random coefficients for coding),
session configuration parameters, or other parameters noted in the
network coding embodiments described below, throughout this
disclosure, and in the documents incorporated herein by reference.
For example, a machine learning system may configure the selection
of a protocol for a transmission, the selection of what network(s)
will be used, the selection of one or more senders, the selection
of one or more routes, the configuration of one or more network
infrastructure nodes, the selection of a destination receiver, the
configuration of a receiver, and the like. In embodiments, each one
of these may be configured by an individual machine learning
system, or the same system may configure an overall configuration
by adjusting various parameters of one or more of the above under
iteration, through a series of trials, optionally seeded by a
training set, which may be based on human configuration of
parameters, or by model-based and/or rule-based configuration.
Feedback to a machine learning system may comprise various
measures, including transmission success or failure, reliability,
efficiency (including cost-based, energy-based and other measures
of efficiency, such as measuring energy per bit transmitted, energy
per bit stored, or the like), quality of transmission, quality of
service, financial yield, operational effectiveness, success at
prediction, success at classification, and others. In embodiments,
a machine learning system may configure network coding parameters
by predicting network behavior or characteristics and may learn to
improve prediction using any of the techniques noted above. In
embodiments, a machine learning system may configure network coding
parameters by classification of one or more network elements and/or
one or more network behaviors and may learn to improve
classification, such as by training and iteration over time. Such
machine-based prediction and/or classification may be used for
self-organization, including by model-based, rule-based, and
machine learning-based configuration. Thus, self-organization of
network coding may use or comprise various combinations or
permutations of model-based systems, rule-based systems, and a
variety of different machine-learning systems (including
classification systems, prediction systems, and deep learning
systems, among others).
[1685] As described in U.S. patent application 2017/0013065,
entitled "Cross-session network communication configuration,"
network coding may involve methods and systems for data
communication over a data channel on a data path between a first
node and a second node and may include maintaining data
characterizing one or more current or previous data communication
connections traversing the data channel and initiating a new data
communication connection between the first node and the second node
including configuring the new data communication connection at
least in part according to the maintained data. The maintained data
may characterize one or more data channels on one or more data
paths between the first node and the second node over which said
one or more current or previous data communication connections
pass. The maintained data may characterize an error rate of the one
or more data channels. The maintained data may characterize a
bandwidth of the one or more data channels. The maintained data may
characterize a round trip time of the one or more data channels.
The maintained data may characterize communication protocol
parameters of the one or more current or previous data
communication connections.
[1686] The communication protocol parameters may include one or
more of a congestion window size, a block size, an interleaving
factor, a port number, a pacing interval, a round trip time, and a
timing variability. The communication protocol parameters may
include two or more of a congestion window size, a block size, an
interleaving factor, a port number, a pacing interval, a round trip
time, and a timing variability.
[1687] The maintained data may characterize forward error
correction parameters associated with the one or more current or
previous data communication connections. The forward error
correction parameters may include a code rate. Initiating the new
data communication connection may include configuring the new data
communication connection according to first data of the maintained
data, the first data is maintained at the first node, and
initiating the new data communication connection includes providing
the first data from the first node to the second node for
configuring the new data communication connection.
[1688] Initiating the new data communication connection may include
configuring the new data communication connection according to
first data of the maintained data, the first data is maintained at
the first node, and initiating the new data communication
connection includes accessing first data at the first node for
configuring the new data communication connection. Any one of these
elements of maintained data, including various parameters of
communication protocol, error correction parameters, connection
parameters, and others, may be provided to the expert system for
supporting self-organization of network coding, including for
execution of rules to set network coding parameters based on the
maintained data, for population of a model, or for configuration of
parameters of a neural net or other artificial intelligence
system.
[1689] Initiating the new data communication connection may include
configuring the new data communication connection according to
first data of the maintained data, the first data being maintained
at the first node, and initiating the new data communication
connection includes accepting a request from the first node for
establishing the new data communication connection between the
first node and the second node, including receiving, at the second
node, at least one message from the first node comprising the first
data for configuring said connection. The method may include
maintaining the new data communication connection between the first
node and the second node, including maintaining communication
parameters, including initializing said communication parameters
according the first data received in the at least one message from
the first node.
[1690] Maintaining the new data communication connection may
include adapting the communication parameters according to feedback
from the first node. The feedback from the first node may include
feedback messages received from the first node. The feedback may
include feedback derived from a plurality of feedback messages
received from the first node. Feedback may relate to any of the
types of feedback noted above, and may be used for self-organizing
the data communication connection using the expert system.
[1691] In some examples, one or more training communication
connections over a data channel on a data path are employed prior
to establishment of data communication connections over the data
channel on the data path. The training communication connections
are used to collect information about the data channel which is
then used when establishing the data communication connections. In
other examples, no training communication connections are employed
and information about the data channel is obtained from one or more
previous or current data communication connection over the data
channel on the data path.
[1692] The present disclosure describes a method for data
communication over a data channel on a data path between a first
node and a second node, the method according to one disclosed
non-limiting embodiment of the present disclosure can include
maintaining data characterizing one or more current or previous
data communication connections traversing the data channel, and
initiating a new data communication connection between the first
node and the second node including configuring the new data
communication connection at least in part according to the
maintained data, wherein the configuration of the new data
communication connection is configured by an expert system.
[1693] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the configuration.
[1694] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to the data channel.
[1695] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system takes a plurality of inputs from a data collector that
accepts data about a machine operating in an industrial
environment
[1696] As described in U.S. patent application 2017/0012861,
entitled "Multi-path network communication," self-organized network
coding under control of an expert system may involve methods and
systems for data communication between a first node and a second
node over a number of data paths coupling the first node and the
second node and may include transmitting messages between the first
node and the second node over the number of data paths, including
transmitting a first subset of the messages over a first data path
of the number of data paths and transmitting a second subset of the
messages over a second data path of the number of data paths. In
situations where the first data path has a first latency and the
second data path has a second latency substantially larger than the
first latency, and messages of the first subset of the messages are
chosen to have first message characteristics and messages of the
second subset are chosen to have second message characteristics,
different from the first message characteristics.
[1697] Messages having the first message characteristics, targeted
for data paths of lower latency, may include time critical
messages; for example, in an industrial environment, messages
relating to a critical fault condition of a machine (e.g.,
overheating, excessive vibration, or any of the other fault
conditions described throughout this disclosure) or relating to a
safety hazard, or a time-critical operational step on which other
processes depend (e.g., completion of a catalytic reaction,
completion of a sub-assembly, or the like in a high-value,
high-speed manufacturing process, a refining process, or the like)
may be designated as time critical (such as by a rule that can be
parsed or processed by a rules engine) or may be learned to be
time-critical by the expert system, such as based on feedback
regarding outcomes over time, including outcomes for similar
machines having similar data in similar industrial environments.
The first subset of the messages and the second subset of the
messages may be determined from a portion of the messages available
at the first node at a time of transmission. At a subsequent time
of transmission, additional messages made available to the first
node may be divided into the first subset and the second subset
based on message characteristics associated with the additional
messages. Division into subsets and selection of what subsets are
targeted to what data path may be undertaken by an expert system.
Messages having the first message characteristics may be associated
with an initial subset of a data set and messages having the second
message characteristics may be associated with a subsequent subset
of the data set. The methods and systems described herein for
selecting inputs for data collection and for multiplexing data may
be organized, such as by an expert system, to configure inputs for
the alternative channels, such as by providing streaming elements
that have real-time significance to the first data path and
providing other elements, such as for long-term, predictive
maintenance, to the other data path. In embodiments, the messages
of the second subset may include messages that are at most n
messages ahead of a last acknowledged message in a sequential
transmission order associated with the messages, wherein n is
determined based on a buffer size at one of the first and second
nodes.
[1698] Messages having the first message characteristics may
include acknowledgement messages and messages having the second
message characteristics may include data messages. Messages having
the first message characteristics may include supplemental data
messages. The supplemental data messages may include data messages
may include redundancy data and messages having the second message
characteristics may include original data messages. The first data
path may include a terrestrial data path and the second data path
may include a satellite data path. The terrestrial data path may
include one or more of a cellular data path, a digital subscriber
line (DSL) data path, a fiber optic data path, a cable internet
based data path, and a wireless local area network data path. The
satellite data path may include one or more of a low earth orbit
satellite data path, a medium earth orbit satellite data path, and
a geostationary earth orbit satellite data path. The first data
path may include a medium earth orbit satellite data path or a low
earth orbit satellite data path and the second data path may
include a geostationary orbit satellite data path.
[1699] The method may further include, for each path of the number
of data paths, maintaining an indication of successful and
unsuccessful delivery of the messages over the data path and
adjusting a congestion window for the data path based on the
indication, which may occur under control of an expert system,
including based on feedback of outcomes of a set of transmissions.
The method may further include, for each path of the number of data
paths, maintaining, at the first node, an indication of whether a
number of messages received at the second node is sufficient to
decode data associated with the messages, wherein the indication is
based on feedback received at the first node over the number of
data paths.
[1700] In another general aspect, a system for data communication
between a number of nodes over a number of data paths coupling the
number of nodes includes a first node configured to transmit
messages to a second node over the number of data paths including
transmitting a first subset of the messages over a first data path
of the number of data paths, and transmitting a second subset of
the messages over a second data path of the number of data
paths.
[1701] In embodiments, the first subset of the messages and the
second subset of the messages for the respective data paths may be
determined from a portion of the messages available at a first node
at a time of transmission. At a subsequent time of transmission,
additional messages made available to the first node may be divided
into a first subset and a second subset based on message
characteristics associated with the additional messages. Messages
having the first message characteristics may be associated with an
initial subset of a data set and messages having the second message
characteristics may be associated with a subsequent subset of the
data set.
[1702] In embodiments, the messages of the second subset may
include messages that are at most n messages ahead of a last
acknowledged message in a sequential transmission order associated
with the messages, wherein n is determined based on a receive
buffer size at the second node. Messages having the first message
characteristics may include acknowledgement messages and messages
having the second message characteristics may include data
messages. Messages having the first message characteristics may
include supplemental data messages. The supplemental data messages
may include data messages including redundancy data and messages
having the second message characteristics may include original data
messages.
[1703] The first node may be further configured to, for each path
of the number of data paths, maintain an indication of successful
and unsuccessful delivery of the messages over the data path and
adjust a congestion window for the data path based on the
indication. The first node may be further configured to maintain an
aggregate indication of whether a number of messages received at
the second node over the number of data paths is sufficient to
decode data associated with the messages and to transmit
supplemental messages based on the aggregate indication, wherein
the aggregate indication is based on feedback from the second node
received at the first node over the number of data paths.
[1704] The present disclosure describes a method for data
communication between a first node and a second node over a
plurality of data paths coupling the first node and the second
node, the method according to one disclosed non-limiting embodiment
of the present disclosure can include transmitting messages between
the first node and the second node over the plurality of data paths
including transmitting a first subset of the messages over a first
data path of the plurality of data paths, and transmitting a second
subset of the messages over a second data path of the plurality of
data paths, wherein the first data path has a first latency and the
second data path has a second latency substantially larger than the
first latency, and messages of the first subset of the messages are
chosen to have first message characteristics and messages of the
second subset are chosen to have second message characteristics,
different from the first message characteristics, wherein the
selection of the first and second subset of message characteristics
is performed automatically under control of an expert system.
[1705] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the selection.
[1706] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to at least one of the data
paths.
[1707] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system takes a plurality of inputs from a data collector that
accepts data about a machine operating in an industrial
environment.
[1708] As described in U.S. patent application 2017/0012868,
entitled "Multiple protocol network communication," self-organized
network coding under control of an expert system may involve
methods and systems for data communication between a first node and
a second node over one or more data paths coupling the first node
and the second node and may include transmitting messages between
the first node and the second node over the data paths, including
transmitting at least some of the messages over a first data path
using a first communication protocol, transmitting at least some of
the messages over a second data path using a second communication
protocol, determining that the first data path is altering a flow
of messages over the first data path due to the messages being
transmitted using the first communication protocol, and in response
to the determining, adjusting a number of messages sent over the
data paths, including decreasing a number of the messages
transmitted over the first data path and increasing a number of
messages transmitted over the second data path. Determination that
the first data path is altering a flow of messages and/or adjusting
the number of messages sent over the data paths may occur under
control of an expert system, such as a rule-based system, a
model-based system, a machine learning system (including deep
learning) or a hybrid of any of those, where the expert system
takes inputs relating to one or more of the data paths, the nodes,
the communication protocols used, or the like. The data paths may
be among devices and systems in an industrial environment, such as
instrumentation systems of industrial machines, one or more mobile
data collectors (optionally coordinated in a swarm), data storage
systems (including network-attached storage), servers and other
information technology elements, any of which may have or be
associated with one or more network nodes. The data paths may be
among any such devices and systems and devices and systems in a
network of any kind (such as switches, routers, and the like) or
between those and ones located in a remote environment, such as in
an enterprise's information technology system, in a cloud platform,
or the like.
[1709] Determining that the first data path is altering the flow of
messages over the first data path may include determining that the
first data path is limiting a rate of messages transmitted using
the first communication protocol. Determining that the first data
path is altering the flow of messages over the first data path may
include determining that the first data path is dropping messages
transmitted using the first communication protocol at a higher rate
than a rate at which the second data path is dropping messages
transmitted using the second communication protocol. The first
communication protocol may be the User Datagram Protocol (UDP), and
the second communication protocol may be the Transmission Control
Protocol (TCP), or vice versa. Other protocols as described
throughout this disclosure may be used.
[1710] The messages may be initially equally divided or divided
according to some predetermined allocation (such as by type, as
noted in connection with other embodiments) across the first data
path and the second data path, such as using a load balancing
technique. The messages may be initially divided across the first
data path and the second data path according to a division of the
messages across the first data path and the second data path in one
or more prior data communication connections. The messages may be
initially divided across the first data path and the second data
path based on a probability that the first data path will alter a
flow of messages over the first data path due to the messages being
transmitted using the first communication protocol.
[1711] The messages may be divided across the first data path and
the second data path based on message type. The message type may
include one or more of acknowledgement messages, forward error
correction messages, retransmission messages, and original data
messages. Decreasing a number of the messages transmitted over the
first data path and increasing a number of messages transmitted
over the second data path may include sending all of the messages
over the second path and sending none of the messages over the
first path.
[1712] At least some of the number of data paths may share a common
physical data path. The first data path and the second data path
may share a common physical data path. The adjusting of the number
of messages sent over the number of data paths may occur during an
initial phase of the transmission of the messages. The adjusting of
the number of messages sent over the number of data paths may
repeatedly occur over a duration of the transmission of the
messages. The adjusting of the number of messages sent over the
number of data paths may include increasing a number of the
messages transmitted over the first data path and decreasing a
number of messages transmitted over the second data path.
[1713] In some examples, the parallel transmission over TCP and UDP
is handled differently from conventional load balancing techniques,
because TCP and UDP both share a low-level data path and
nevertheless have very different protocol characteristics.
[1714] In some examples, approaches respond to instantaneous
network behavior and learn the network's data handling policy and
state by probing for changes. In an industrial environment, this
may include learning policies relating to authorization to use
aspects of a network; for example, a SCADA system may allow a data
path to be used only by a limited set of authorized users,
services, or applications, because of the sensitivity of underlying
machines or processes that are under control (including remote
control) via the SCADA system and concern over potential for
cyberattacks. Unlike conventional load-balancers, which assume each
data path is unique and does not affect the other, approaches may
recognize that TCP and UDP share a low-level data path and directly
affect each other. Additionally, TCP provides in-order delivery and
retransmits data (along with flow control, congestion control,
etc.) whereas UDP does not. This uniqueness requires additional
logic provided by the methods and systems disclosed herein that may
include mapping specific message types to each communication
protocol, such as based at least in part on the different
properties of the protocols (e.g., expect longer jitter over TCP,
expect out-of-order delivery on UDP). For example, the system may
refrain from coding over packets sent through TCP, since it is
reliable, but may send forward error correction over UDP to add
redundancy and save bandwidth. In some examples, a larger ACK
interval is used for ACKing TCP data.
[1715] By employing the techniques described herein, approaches
distribute data over TCP and UDP data paths to achieve optimal or
near-optimal throughput, such as in situations where a network
provider's policies treat UDP unfairly (as compared to conventional
systems that simply use UDP if possible and fall back to TCP if
not).
[1716] A method for data communication between a first node and a
second node over a plurality of data paths coupling the first node
and the second node, the method comprising:
transmitting messages between the first node and the second node
over the plurality of data paths including transmitting at least
some of the messages over a first data path of the plurality of
data paths using a first communication protocol, and transmitting
at least some of the messages over a second data path of the
plurality of data paths using a second communication protocol;
determining that the first data path is altering a flow of messages
over the first data path due to the messages being transmitted
using the first communication protocol, and in response to the
determining, adjusting a number of messages sent over the plurality
of data paths including decreasing a number of the messages
transmitted over the first data path and increasing a number of
messages transmitted over the second data path, wherein altering
the flow of messages is performed automatically under control of an
expert system.
[1717] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the alteration of the flow.
[1718] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to at least one of the data
paths.
[1719] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system takes a plurality of inputs from a data collector that
accepts data about a machine operating in an industrial
environment.
[1720] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the first
communication protocol is User Datagram Protocol (UDP).
[1721] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the second
communication protocol is Transmission Control Protocol (TCP).
[1722] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the messages
are initially divided across the first data path and the second
data path using a load balancing technique.
[1723] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the messages
are initially divided across the first data path and the second
data path according to a division of the messages across the first
data path and the second data path in one or more prior data
communication connections.
[1724] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the messages
are initially divided across the first data path and the second
data path based on a probability that the first data path will
alter a flow of messages over the first data path due to the
messages being transmitted using the first communication
protocol.
[1725] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the
probability is determined by an expert system.
[1726] As described in U.S. patent application 2017/0012884,
entitled "Message reordering timers," self-organized network coding
under control of an expert system may involve methods and systems
for data communication from a first node to a second node over a
data channel coupling the first node and the second node and may
include receiving data messages at the second node, the messages
belonging to a set of data messages transmitted in a sequential
order from the first node, sending feedback messages from the
second node to the first node, the feedback messages characterizing
a delivery status of the set of data messages at the second node,
including maintaining a set of one or more timers according to
occurrences of a number of delivery order events, the maintaining
including modifying a status of one or more timers of the set of
timers based on occurrences of the number of delivery order events,
and deferring sending of said feedback messages until expiry of one
or more of the set of one or more timers. The data channels may be
among devices and systems in an industrial environment, such as
instrumentation systems of industrial machines, one or more mobile
data collectors (optionally coordinated in a swarm), data storage
systems (including network-attached storage), servers and other
information technology elements, any of which may have or be
associated with one or more network nodes. The data channels may be
among any such devices and systems and devices and systems in a
network of any kind (such as switches, routers, and the like) or
between those and ones located in a remote environment, such as in
an enterprise's information technology system, in a cloud platform,
or the like. Determination that that timers are required,
configuration of timers, and initiation of the user of timers may
occur under control of an expert system, such as a rule-based
system, a model-based system, a machine learning system (including
deep learning) or a hybrid of any of those, where the expert system
takes inputs relating to one or more of the types of communications
occurring, the data channels, the nodes, the communication
protocols used, or the like.
[1727] The set of one or more timers may include a first timer and
the first timer may be started upon detection of a first delivery
order event, the first delivery order event being associated with
receipt of a first data message associated with a first position in
the sequential order prior to receipt of one or more missing
messages associated with positions preceding the first position in
the sequential order. The method may include sending the feedback
messages indicating a successful delivery of the set of data
messages at the second node upon detection of a second delivery
order event, the second delivery order event being associated with
receipt of the one or more missing messages prior to expiry of the
first timer. The method may include sending said feedback messages
indicating an unsuccessful delivery of the set of data messages at
the second node upon expiry of the first timer prior to any of the
one or more missing messages being received. The set of one or more
timers may include a second timer and the second timer is started
upon detection of a second delivery order event, the second
delivery order event being associated with receipt of some but not
all of the missing messages prior to expiry of the first timer. The
method may include sending feedback messages indicating an
unsuccessful delivery of the set of data messages at the second
node upon expiry of the second timer prior to receipt of the
missing messages. The method may include sending feedback messages
indicating a successful delivery of the set of data messages at the
second node upon detection of a third delivery order event, the
third delivery order event being associated with receipt of the
missing messages prior to expiry of the second timer.
[1728] In another general aspect, a method for data communication
from a first node to a second node over a data channel coupling the
first node and the second node includes receiving, at the first
node, feedback messages indicative of a delivery status of a set of
data messages transmitted in a sequential order to the second node
from the second node, maintaining a size of a congestion window at
the first node including maintaining a set of one or more timers
according to occurrences of a number of feedback events, the
maintaining including modifying a status of one or more timers of
the set of timers based on occurrences of the number of feedback
events, and delaying modification of the size of the congestion
window until expiry of one or more of the set of one or more
timers.
[1729] The set of one or more timers may include a first timer and
the first timer may be started upon detection of a first feedback
event, the first feedback event being associated with receipt of a
first feedback message indicating successful delivery of a first
data message having first position in the sequential order prior to
receipt of one or more feedback messages indicating successful
delivery of one or more other data messages having positions
preceding the first position in the sequential order. The method
may include cancelling modification of the congestion window upon
detection of a second feedback event, the second feedback event
being associated with receipt of one or more feedback messages
indicating successful delivery of the one or more other data
messages prior to expiry of the first timer. The method may include
modifying the congestion window upon expiry of the first timer
prior to receipt of any feedback message indicating successful
delivery of the one or more other data messages.
[1730] The set of one or more timers may include a second timer and
the second timer may be started upon detection of a third feedback
event, the third feedback event being associated with receipt of
one or more feedback messages indicating successful delivery of
some but not all of the one or more other data messages prior to
expiry of the first timer. The method may include modifying the
size of the congestion window upon expiry of the second timer prior
to receipt of one or more feedback messages indicating successful
delivery of the one or more other data messages. The method may
include cancelling modification of the size of the congestion
window upon detection of a fourth feedback event, the fourth
feedback event being associated with receipt one or more feedback
messages indicating successful delivery of the one or more other
data messages prior to expiry of the second timer.
[1731] In another general aspect, a system for data communication
between a number of nodes over a data channel coupling the number
of nodes includes a first node of the number of nodes configured to
receive, at the first node, feedback messages indicative of a
delivery status of a set of data messages transmitted in a
sequential order to the second node from the second node, maintain
a size of a congestion window at the first node including
maintaining a set of one or more timers according to occurrences of
a number of feedback events, the maintaining including modifying a
status of one or more timers of the set of timers based on
occurrences of the number of feedback events, and delaying
modification of the size of the congestion window until expiry of
one or more of the set of one or more timers.
[1732] The present disclosure describes a method for data
communication from a first node to a second node over a data
channel coupling the first node and the second node, the method
according to one disclosed non-limiting embodiment of the present
disclosure can include determining, using an expert system, based
on at least one condition of the data channel, whether one or more
timers will be used to manage the data communication and, upon such
determination receiving data messages at the second node, the
messages belonging to a set of data messages transmitted in a
sequential order from the first node, sending feedback messages
from the second node to the first node, the feedback messages
characterizing a delivery status of the set of data messages at the
second node, including maintaining a set of one or more timers
according to occurrences of a plurality of delivery order events,
the maintaining including modifying a status of one or more timers
of the set of timers based on occurrences of the plurality of
delivery order events, and deferring sending of said feedback
messages until expiry of one or more of the set of one or more
timers.
[1733] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the determination whether to use one or more timers.
[1734] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to at least one of the data
paths.
[1735] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system takes a plurality of inputs from a data collector that
accepts data about a machine operating in an industrial
environment.
[1736] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the set of
one or more timers includes a first timer and the first timer is
started upon detection of a first delivery order event, the first
delivery order event being associated with receipt of a first data
message associated with a first position in the sequential order
prior to receipt of one or more missing messages associated with
positions preceding the first position in the sequential order.
[1737] As described in U.S. patent application 2017/0012885,
entitled, "Network Communication Recoding Node," self-organized
network coding under control of an expert system may involve
methods and systems for modifying redundancy information associated
with encoded data passing from a first node to a second node over
data paths and may include receiving first encoded data including
first redundancy information at an intermediate node from the first
node via a first channel connecting the first node and the
intermediate node, the first channel having first channel
characteristics, and transmitting second encoded data including
second redundancy information from the intermediate node to the
second node via a second channel connecting the intermediate node
and the second node, the second channel having second channel
characteristics. A degree of redundancy associated with the second
redundancy information may be determined by modifying the first
redundancy information based on one or both of the first channel
characteristics and the second channel characteristics without
decoding the first encoded data. The data paths may be among
devices and systems in an industrial environment (each acting as
one or more nodes for sending, receiving, or transmitting data),
such as instrumentation systems of industrial machines, one or more
mobile data collectors (optionally coordinated in a swarm), data
storage systems (including network-attached storage), servers and
other information technology elements, any of which may have or be
associated with one or more network nodes. The data paths may be
among any such devices and systems and devices and systems in a
network of any kind (such as switches, routers, and the like) or
between those and ones located in a remote environment, such as in
an enterprise's information technology system, in a cloud platform,
or the like. Modifying the redundancy information may occur by or
under control of an expert system, such as a rule-based system, a
model-based system, a machine learning system (including deep
learning) or a hybrid of any of those, where the expert system
takes inputs relating to one or more of the data paths, the nodes,
the communication protocols used, or the like. Redundancy may
result from (and may be identified at least in part based on), the
combination or multiplexing of data from a set of data inputs, such
as described throughout this disclosure.
[1738] Modifying the first redundancy information may include
adding redundancy information to the first redundancy information.
Modifying the first redundancy information may include removing
redundancy information from the first redundancy information. The
second redundancy information may be further formed by modifying
the first redundancy information based on feedback from the second
node indicative of successful or unsuccessful delivery of the
encoded data to the second node. The first encoded data and the
second encoded data may be encoded, such as using a random linear
network code or a substantially random linear network code.
Modifying the first redundancy information based on one or both of
the first channel characteristics and the second channel
characteristics may include modifying the first redundancy
information based on one or more of a block size, a congestion
window size, and a pacing rate associated with the first channel
characteristics and/or the second channel characteristics.
[1739] The method may include sending a feedback message from the
intermediate node to the first node acknowledging receipt of one or
more messages at the intermediate node. The method may include
receiving a feedback message from the second node at the
intermediate node and, in response to receiving the feedback
message, transmitting additional redundancy information to the
second node.
[1740] In another general aspect, a system for modifying redundancy
information associated with encoded data passing from a first node
to a second node over a number of data paths includes an
intermediate node configured to receive first encoded data
including first redundancy information from the first node via a
first channel connecting the first node and the intermediate node,
the first channel having first channel characteristics and transmit
second encoded data including second redundancy information from
the intermediate node to the second node via a second channel
connecting the intermediate node and the second node, the second
channel having second channel characteristics. A degree of
redundancy associated with the second redundancy information is
determined by modifying the first redundancy information based on
one or both of the first channel characteristics and the second
channel characteristics without decoding the first encoded
data.
[1741] The present disclosure describes a method for modifying
redundancy information associated with encoded data passing from a
first node to a second node over a plurality of data paths, the
method according to one disclosed non-limiting embodiment of the
present disclosure can include receiving first encoded data
including first redundancy information at an intermediate node from
the first node via a first channel connecting the first node and
the intermediate node, the first channel having first channel
characteristics, transmitting second encoded data including second
redundancy information from the intermediate node to the second
node via a second channel connecting the intermediate node and the
second node, the second channel having second channel
characteristics, wherein a degree of redundancy associated with the
second redundancy information is determined by modifying the first
redundancy information based on one or both of the first channel
characteristics and the second channel characteristics without
decoding the first encoded data, including modifying the first
redundancy information based on one or more of a block size, a
congestion window size, and a pacing rate associated with the first
channel characteristics and/or the second channel characteristics,
wherein modifying the first redundancy information occurs under
control of an expert system.
[1742] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the modification of the redundancy information.
[1743] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to at least one of the data
paths.
[1744] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system takes a plurality of inputs from a data collector that
accepts data about a machine operating in an industrial
environment.
[1745] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein modifying the
first redundancy information includes adding redundancy information
to the first redundancy information.
[1746] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein modifying the
first redundancy information includes removing redundancy
information from the first redundancy information.
[1747] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the second
redundancy information is further formed by modifying the first
redundancy information based on feedback from the second node
indicative of successful or unsuccessful delivery of the encoded
data to the second node.
[1748] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the first
encoded data and the second encoded data are encoded using a random
linear network code.
[1749] As described in U.S. patent application 2017/0012905,
entitled "Error correction optimization," self-organized network
coding under control of an expert system may involve methods and
systems for data communication between a first node and a second
node over a data path coupling the first node and the second node
and may include transmitting a segment of data from the first node
to the second node over the data path as a number of messages, the
number of messages being transmitted according to a transmission
order. A degree of redundancy associated with each message of the
number of messages is determined based on a position of said
message in the transmission order. The data paths may be among
devices and systems in an industrial environment (each acting as
one or more nodes for sending, receiving, or transmitting data),
such as instrumentation systems of industrial machines, one or more
mobile data collectors (optionally coordinated in a swarm), data
storage systems (including network-attached storage), servers and
other information technology elements, any of which may have or be
associated with one or more network nodes. The data paths may be
among any such devices and systems and devices and systems in a
network of any kind (such as switches, routers, and the like) or
between those and ones located in a remote environment, such as in
an enterprise's information technology system, in a cloud platform,
or the like. Determining a transmission order may occur by or under
control of an expert system, such as a rule-based system, a
model-based system, a machine learning system (including deep
learning) or a hybrid of any of those, where the expert system
takes inputs relating to one or more of the data paths, the nodes,
the communication protocols used, or the like. Redundancy may
result from (and may be identified at least in part based on), the
combination or multiplexing of data from a set of data inputs, such
as described throughout this disclosure.
[1750] The degree of redundancy associated with each message of the
number of messages may increase as the position of the message in
the transmission order is non-decreasing. Determining the degree of
redundancy associated with each message of the number of messages
based on the position (i) of the message in the transmission order
is further based on one or more of delay requirements for an
application at the second node, a round trip time associated with
the data path, a smoothed loss rate (P) associated with the
channel, a size (N) of the data associated with the number of
messages, a number (ai) of acknowledgement messages received from
the second node corresponding to messages from the number of
messages, a number (fi) of in-flight messages of the number of
messages, and an increasing function (g(i)) based on the index of
the data associated with the number of messages.
[1751] The degree of redundancy associated with each message of the
number of messages may be defined as: (N+g(i)-ai)/(1-p)-fi. g(i)
may be defined as a maximum of a parameter m and N-i. g(i) may be
defined as N-p(i) where p is a polynomial, with integer rounding as
needed. The method may include receiving, at the first node, a
feedback message from the second node indicating a missing message
at the second node and, in response to receiving the feedback
message, sending a redundancy message to the second node to
increase a degree of redundancy associated with the missing
message. The method may include maintaining, at the first node, a
queue of preemptively computed redundancy messages and, in response
to receiving the feedback message, removing some or all of the
preemptively computed redundancy messages from the queue and adding
the redundancy message to the queue for transmission. The
redundancy message may be generated and sent on-the-fly in response
to receipt of the feedback message.
[1752] The method may include maintaining, at the first node, a
queue of preemptively computed redundancy messages for the number
of messages and, in response to receiving a feedback message
indicating successful delivery of the number of messages, removing
any preemptively computed redundancy messages associated with the
number of messages from the queue of preemptively computed
redundancy messages. The degree of redundancy associated with each
of the messages may characterize a probability of correctability of
an erasure of the message. The probability of correctability may
depend on a comparison of between the degree of redundancy and a
loss probability.
[1753] The present disclosure describes a method for data
communication between a first node and a second node over a data
path coupling the first node and the second nod, the method
according to one disclosed non-limiting embodiment of the present
disclosure can include transmitting a segment of data from the
first node to the second node over the data path as a plurality of
messages, the plurality of messages being transmitted according to
a transmission order, wherein a degree of redundancy associated
with each message of the plurality of messages is determined based
on a position of said message in the transmission order, wherein
the transmission order is determined under control of an expert
system.
[1754] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the transmission order.
[1755] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to at least one of the data
paths.
[1756] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system takes a plurality of inputs from a data collector that
accepts data about a machine operating in an industrial
environment.
[1757] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the degree of
redundancy associated with each message of the plurality of
messages increases as the position of the message in the
transmission order is non-decreasing.
[1758] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein determining
the degree of redundancy associated with each message of the
plurality of messages based on the position (i) of the message in
the transmission order is further based on one or more of
application delay requirements, a round trip time associated with
the data path, a smoothed loss rate (P) associated with the
channel, a size (N) of the data associated with the plurality of
messages, a number (ai) of acknowledgement messages received from
the second node corresponding to messages from the plurality of
messages, a number (fi) of in-flight messages of the plurality of
messages, and an increasing function (g(i)) based on the index of
the data associated with the plurality of messages.
[1759] As described in U.S. patent application Ser. No. 14/935,885,
entitled, "Packet Coding Based Network Communication,"
self-organized network coding under control of an expert system may
involve methods and systems for data communication between a first
node and a second node over a path and may include estimating a
rate at which loss events occur, where a loss event is either an
unsuccessful delivery of a single packet to the second data node or
an unsuccessful delivery of a plurality of consecutively
transmitted packets to the second data node, and sending redundancy
messages at the estimated rate at which loss events occur. An
expert system may be used to estimate the rate at which loss events
occur.
[1760] A method for data communication from a first node to a
second node over a data channel coupling the first node and the
second node such as in an industrial environment, includes
receiving messages at the first node, from the second node,
including receiving messages comprising data that depend at least
in part of characteristics of the channel coupling the first node
and the second node, transmitting messages from the first node to
the second node, including applying forward error correction
according to parameters determined from the received messages, the
parameters determined from the received messages including at least
two of a block size, an interleaving factor, and a code rate. The
method may occur under control of an expert system.
[1761] The present disclosure describes a method for data
communication from a first node in an industrial environment to a
second node over a data channel coupling the first node and the
second node, the method according to one disclosed non-limiting
embodiment of the present disclosure can include receiving messages
at the first node from the second node, including receiving
messages including data that depend at least in part of
characteristics of the channel coupling the first node and the
second node, transmitting messages from the first node to the
second node, including applying error correction according to
parameters determined from the received messages, the parameters
determined from the received messages including at least two of a
block size, an interleaving factor, and a code rate, wherein
applying the error correction occurs under control of an expert
system.
[1762] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system uses at least one of a rule and a model to set a parameter
of the error correction.
[1763] A further embodiment of any of the foregoing embodiments of
the present disclosure may include situations wherein the expert
system is a machine learning system that iteratively configures at
least one of a set of inputs, a set of weights, and a set of
functions based on feedback relating to at least one of the data
paths.
[1764] As depicted in FIG. 180, a cloud platform for supporting
deployments of devices in the Internet of Things (IoT), such as
within industrial environments, may include various components,
modules, services, elements, applications, interfaces, and other
elements (collectively referred to as the "cloud platform 13000"),
which may include a policy automation engine 13002 and a data
marketplace 13008. The cloud platform 13000 may include, integrate
with, or connect to various devices 13006, a cloud computing
environment 13068, data pools 13070, data collectors 13020 and
sensors 13024. The cloud platform 13000 may also include systems
and capabilities for self-organization 13012, machine learning
13014 and rights management 13016.
[1765] Within the cloud platform 13000, various components may be
deployed in a wide range of architectures and arrangements. In
embodiments, devices 13006 may connect to, integrate with, or be
deployed within a cloud computing environment 13068, the policy
automation engine 13002, the data marketplace 13008, the data
collectors 13020, as well as systems and capabilities for
self-organization 13012, machine learning 13014 and rights
management 13016. Devices 13006 may connect to or integrate with
the policy automation engine 13002, data marketplace 13008, data
collectors 13020 and systems or capabilities for self-organization
13012, machine learning 13014 and rights management 13016, either
directly or through the cloud computing environment 13068.
[1766] Devices 13006 may be IoT devices, including IoT devices,
such as for collecting, exchanging and managing information
relating to machines, personnel, equipment, infrastructure
elements, components, parts, inventory, assets, and other features
of a wide range of industrial environments, such as those described
throughout this disclosure. Devices 13006 may also connect via
various protocols 13004, such as networking protocols, streaming
protocols, file transfer protocols, data transformation protocols,
software operating system protocols, and the like. Devices may
connect to the policy automation engine 13002, such as for
executing policies that may be deployed within the cloud platform
13000, such as governing activities, permissions, rules, and the
like within the platform 13000. Devices 13006 may also connect to
data streams 13010 within the data marketplace 13008.
[1767] Data pools 13070 may connect to or integrate with the cloud
computing environment 13068, data collectors 13020 and the data
marketplace 13008, policy automation engine 13002,
self-organization 13012, machine learning 13014 and rights
management 13016 capabilities. Data pools 13070 may be included
within the cloud computing environment 30 or be external to the
cloud computing environment 13068. As a result, connections to the
data pools 13070 may be made directly to the data pools 13070,
through cloud connections to the data pools 13070 or through a
combination of direct and cloud connections to the data pools
13070. Data pools 13070 may also be included within the data
marketplace 13008 or external to the data marketplace 13008.
[1768] Data pools 13070 may include a multiplexer (MUX) 13022 and
also connect to self-organization 13012, machine learning 13014 and
rights management capabilities. The MUX 13022 may connect to
sensors 13024, collect data from sensors 13024 and integrate data
collected from sensors 13024 into a single set of data. In an
exemplary and non-limiting embodiment, data pools 13070, data
collectors 13020 and sensors 13024 may be included within an
industrial environment 13018.
[1769] A policy automation engine 13002 and data marketplace 13008
may be used in a variety of industrial environments 13018.
Industrial environments 13018 may include aerospace environments,
agriculture environment, assembly line environments, automotive
environments, and chemical and pharmaceutical environments.
Industrial environments 13018 may also include food processing
environments, industrial component environments, mining
environments, oil and gas environments, particularly oil and gas
production environments, truck and car environments and the
like.
[1770] Similarly, devices 13006 may include a variety of devices
that may operate within the industrial environments or that may
collect data with respect to other such devices. Among many
examples, devices 13006 may include agitators, including turbine
agitators, airframe control surface vibration devices, catalytic
reactors and compressors. Devices 13006 may also include conveyors
and lifters, disposal systems, drive trains, fans, irrigation
systems and motors. Devices 13006 may also include pipelines,
electric powertrains, production platforms, pumps, such as water
pumps, robotic assembly systems, thermic heating systems, tracks,
transmission systems and turbines. Devices 13006 may operate within
a single industrial environment 13018 or multiple industrial
environments 13018. For example, a pipeline device may operate
within an oil and gas environment, while a catalytic reactor may
operate in either an oil and gas production environment or a
pharmaceutical environment.
[1771] The policy automation engine 13002 may be a cloud-based
policy automation engine 13002. A policy automation engine 13002
may be used to create, deploy, and/or manage an interconnected set
of policies 13030, rules 13028 and protocols 13004, such as
policies relating to security, authorization, permissions, and the
like. For example, policies may govern what users, applications,
services, systems, devices, or the like may access an IoT device,
may read data from an IoT device, may subscribe to a stream from an
IoT device, may write data to an IoT device, may establish a
network connection with an IoT device, may provision an IoT device,
may collaborate with an IoT device, or the like.
[1772] The policy automation engine 13002 may generate and manage
policies 13030. The policy generation engine may be the centralized
policy management system for the cloud platform 13000.
[1773] Policies 13030 generated and managed by the policy
automation engine 13002 may deploy a large number of rules 13028 to
permit access to and use of different aspects of IoT devices.
Policies 13030 may include IoT device creation policies 13032, IoT
device deployment policies 13034, IoT device management policies
13036 and the like. The policies 13030 may be communicated to
devices 13006 through protocols 13004 or directly from the policy
automation engine 13002.
[1774] For example, in an exemplary and non-limiting embodiment,
the policy automation engine 13002 may manage policies 13030 and
create protocols 13004 that specify and enforce roles 13026 and
permissions 13074 for workers, related to how the workers may use
data provided by IoT devices. Workers may be human workers or
machine workers.
[1775] In additional exemplary and non-limiting embodiments,
policies 13030 may be used to automate remediation processes.
Remediation processes may be performed when a system is partially
disabled, when equipment fails and when an entire system may be
disabled. Remediation processes may include instructions to
initiate system restarts, bypass or replace equipment, notify
appropriate stakeholders of the condition and the like. The policy
automation engine 13002 may also include policies 13030 that
specify the roles 13026 and permissions 13074 required for users
13072 to initiate or otherwise act upon the remediation or other
processes.
[1776] The policy automation engine 13002 may also specify and
detect conditions. Conditions may determine when policies 13030 are
distributed or otherwise acted upon. Conditions may include
individual conditions, sets of conditions, independent conditions,
interdependent conditions, and the like.
[1777] In an exemplary and non-limiting embodiment of an
independent condition, the policy automation engine 13002 may
determine that the failure of a non-critical device 13006 does not
require notification of the system operator. In an exemplary and
non-limiting embodiment of an interdependent set of conditions, the
policy automation engine 13002 may determine that the failure of
two non-critical system devices 13006 does require notification of
the system operator, as the failure of two non-critical system
devices 13006 may be an early indicator of a possible system-wide
failure.
[1778] As depicted in FIG. 181, the policy automation engine 13002
may include compliance policies 13050 and fault, configuration,
accounting, provisioning, and security (FCAPS) policies 13052.
Policies 13030 may connect to rules 13028, protocols 13004 and
policy inputs 13048.
[1779] Policies 13030 may provide input to rules 13028 and provide
information related to how roles 13026, permissions 13074 and uses
130280 are defined. Policies 13030 may receive policy inputs 13048
and incorporate policy inputs 13048 as policy parameters that are
included within policies 13030. Policies 13030 may provide inputs
to protocols 13004 and be included within protocols 13004 that are
used to create, deploy and manage devices 13006.
[1780] Compliance policies 13050 may include data ownership
policies, data analysis policies, data use policies, data format
policies, data transmission policies, data security policies, data
privacy policies, information sharing policies, jurisdictional
policies, and the like. Data transmission policies may include
cross jurisdictional data transmission policies.
[1781] Data ownership policies may indicate policies 13030 that
manage who controls data, who can use data, how the data can be
used and the like. Data analysis policies may indicate what data
holders can do with data that they are permitted to access, as well
as determine what data they can look at and what data may be
combined with other data. For example, a data holder may look at
aggregated user data but not individual user data. Data use
policies may indicate how data may be used and under what
circumstances data may be used. Data format policies may indicate
standard formats and mandated formats permitted for the handling of
data. Data transmission policies, including cross jurisdictional
data transmission policies, may determine the policies 13030 that
specify how inter-jurisdictional and intra-jurisdictional
transmission of data may be handled Data security policies may
determine how data at rest, for example stored data, as well
transmitted data is required to be secured.
[1782] Data privacy policies may determine how data may or may not
be shared, for example within an organization and external to an
organization. Information sharing policies may determine how data
may be sold, shared and under what circumstances information can be
sold and shared. Jurisdictional policies may determine who controls
data, when and where the data may be controlled, for data within
and transmitted across boundaries.
[1783] FCAPS policies 13052 may include fault management policies,
configuration management policies, accounting management policies,
provisioning management policies, and security management policies.
Fault management policies may specify policies 13030 used to handle
device faults. Configuration management policies may specify
policies used to configure devices 13006. Accounting management
policies may specify policies 13030 used for device accounting
purposes, such as reporting, billing and the like. Provisioning
management policies may specify policies 13030 used to provision
services on devices 13006. Security management policies may specify
policies 13030 used to secure devices 13006.
[1784] Policy inputs 13048 may be received from a policy input
interface 13046. Policy inputs 13048 may include standards-based
policy inputs 13044 and other policy inputs 13048 Standards-based
policy inputs 13044 may include inputs related to standard data
formats, standard rule sets and other standards-related information
set by standards bodies, for example.
[1785] Other policy inputs 13048 may include a wide range of
information related industry-specific policies, cross-industry
policies, manufacturer-specific policies, device-specific policies
13030 and the like. Policy inputs 13048 may connect to a cloud
computing environment 13068 and be provided through a policy input
interface 13046. The policy input interface 13046 may collect
policy inputs 13048 provided by machines or entered by human
operators.
[1786] As depicted in FIG. 180, a data marketplace 13008 may
include data streams 13010, a data marketplace input interface,
data marketplace inputs 13056, a data payment allocation engine
13038, marketplace value rating engine 13040, a data brokering
engine 13042, a marketplace self-organization engine 13076 and one
or more data pools 13070. The data marketplace 13008 may be
included within the cloud networking environment 30 or externally
connected to the cloud networking environment 13068. Data pools
13070 may also be included within the cloud networking environment
13068 or may be externally connected to the cloud networking
environment 13068.
[1787] The data marketplace 13008 may connect to data pools 13070
directly, for example if the data marketplace 13008 and data pools
13070 are located in the same physical location. The data
marketplace 13008 may connect to data pools 13070 via a cloud
networking environment 30, for example if the data marketplace
13008 and data pools 13070 are located in different physical
locations.
[1788] The data marketplace 13008 may connect to and receive
inputs. The data marketplace 13008 may receive marketplace inputs
through data interfaces, for example one or more data collectors
13020. The data collectors 13020 may be multiplexing data
collectors. Inputs received through the data collectors 13020 may
be received as one or more than one data streams 13010 from one or
more than one data collectors 13020 and integrated into additional
data streams 13010 by the multiplexer (MUX) 13022.
[1789] The data streams 13010 may also include data from the data
pools 60. Data marketplace inputs, data streams 13010 and data
pools 13070 may include metrics and measures of success of the data
marketplace 13008. The metrics and measures of success of the data
marketplace 13008 may then be used by the machine learning
capability 13014 to configure one or more parameters of the data
marketplace 13008.
[1790] Inputs may be consortia inputs 13054. Consortia inputs 13054
may be received from consortia. Consortia may include energy
consortia, healthcare consortia, manufacturing consortia, smart
city consortia, transportation consortia and the like. Consortia
may be pre-existing consortia or new consortia.
[1791] In an exemplary and non-limiting embodiment, new consortia
may be formed as a result of the data marketplace 13008 making
available particular data types and data combinations. The data
brokering engine 13042 may allow consortia members to trade
information. The data brokering engine 13042 may allow consortia
members to trade information based on information value, as
calculated by the marketplace value rating engine 13040, for
example.
[1792] The data marketplace 13008 may also connect to
self-organization 13012, machine learning 13014 and rights
management 13016 capabilities. Rights management capabilities 13016
may include rights.
[1793] Rights may include business strategy and solution rights,
liaison rights 13058, marketing rights 13078, security rights
13060, technology rights 13062, testbed rights 13064 and the like.
Business strategy and solution lifecycle rights may include
business strategy and planning rights, industrial internet system
design rights, project management rights, solution evaluation and
contractual aspects rights. Liaison rights 13058 may include
standards organization rights, open-source community rights,
certification and testing body rights and governmental organization
rights. Marketing rights 13078 may include communication rights,
energy rights, healthcare rights, marketing-security rights, retail
operation rights, smart factory rights and thought leadership
rights. Security rights 13060 may include driving rights that drive
industry consensus, promote security best practices and accelerate
the adoption of security best practices.
[1794] Technology rights 13062 may include architecture rights,
connectivity rights, distributed data management and
interoperability rights, industrial analytics rights, innovation
rights, IT/OT rights, safety rights, vocabulary rights, use case
rights and liaison rights 13058. Testbed rights 13064 may include
rights to implement of specific use cases and scenarios, as well as
rights to produce testable outcomes to confirm that an
implementation conforms to expected results, for example. Testbed
rights 13064 may also include rights to explore untested or
existing technologies working together, for example
interoperability testing, generate new and potentially disruptive
products and services and generate requirements and priorities for
standards organizations, consortia and other stakeholder
groups.
[1795] The rights management capability may assign different rights
to different participants in the data marketplace 13008. In an
exemplary and non-limiting embodiment, manufacturers or remote
maintenance organizations (RMOs). Participants may be assigned
rights to information based on their equipment or proprietary
methods. The data marketplace 13008 may then ensure that only the
appropriate data streams 13010 are made available to the market,
based on the assigned rights.
[1796] The rights management capability 13016 may manage
permissions to access the data in the marketplace 13008. One or
more parameters of the rights management capability 13016 may be
automatically configured by the machine learning capability 13014
and may be based on a metric of success of the data marketplace
13008. The machine learning engine 13014 may also use the metric
and measure of success to configure a user interface. The user
interface may present a data element of the user of the data
marketplace 13008. The user interface may also present one or more
mechanisms by which a user of the data marketplace 13008 may obtain
access to one or more of the data elements.
[1797] The data payment allocation engine 13038 may allocate data
marketplace payments. The data payment allocation engine 13038 may
allocate data marketplace payments according to the value of a data
stream 13010, the value of a contribution to a data stream 13010
and the like. This type of payment allocation may allow the data
marketplace 13008 to allocate payments to data contributors, based
on the value of the data contributions.
[1798] For example, contributors of data to a higher-value data
stream 13010 may receive higher payments than contributors of data
to lower-value data streams 13010. Similarly, data marketplace
participants, for example IoT device manufacturers and system
integrators, may be rated or ranked by the value of the data or the
power of the configurations they provide and support.
[1799] The data marketplace 13008 may be a self-organizing data
marketplace. A self-organizing data marketplace may self-organize
using self-organization capabilities 13012. Self-organization
capabilities 13012 may be learned, developed and optimized using
artificial intelligence (AI) capabilities. AI capabilities may be
provided by the machine learning 13014 capability, for example.
Self-organization may occur via an expert system and may be based
on the application of a model, one or more rules, or the like.
Self-organization may occur via a neural network or deep learning
system, such as by optimizing variations of the organization of the
data pool over time based on feedback to one or more measures of
success. Self-organization may occur by a hybrid or combination of
a rule-based system, model-based system, and neural network or
other AI system. Various capabilities may be self-organized, such
as how data elements are presented in the user interface of the
marketplace, what data elements are presented, what data streams
are obtained as inputs to the marketplace, how data elements are
described, what metadata is provided with data elements, how data
elements are stored (such as in a cache or other "hot" storage or
in slower, but less expensive storage locations), where data
elements are stored (such as in edge elements of a network), how
data elements are combined, fused or multiplexed, or the like.
Feedback to self-organization may include various metrics and
measures of success, such as profit measures, yield measures,
ratings (such as by users, purchasers, licensees, reviewers, and
the like), indicators of interest (such as clickstream activity,
time spent on a page, time spent reviewing elements and links to
data elements), and others as described throughout this
disclosure.
[1800] Data marketplace inputs 13056, data streams 13010 and data
pools 13070 may be organized, based on metrics and measures of
success of the data marketplace 13056. Data marketplace inputs
13056, data streams 13010 and data pools 13070 may be organized by
the self-organization capability 13012, allowing the marketplace
inputs 13056, data streams 13010, and data pools 60 to be organized
automatically, without requiring interaction by a user of the data
marketplace. 13008.
[1801] The metric and measure of success may also be used to
configure the data brokering engine 13042 to execute a transaction
among at least two marketplace participants. The machine learning
engine 13014 may use the metric of success to configure the data
brokering engine 13042 automatically, without requiring user
intervention. The metric of success may also be used by a pricing
engine, for example the marketplace value rating engine 13040, to
set the price of one or more data elements within the data
marketplace 13008.
[1802] In an exemplary and non-limiting embodiment, the
self-organizing data marketplace may self-organize to determine
which type of data streams 13010 are the most valuable and offer
the most valuable and other data streams 13010 for sale. The
calculation of data stream value may be performed by the
marketplace value rating engine 13040.
[1803] In embodiments, a policy automation system for a data
collection system in an industrial environment may comprise: a
policy input interface structured to receive policy inputs relating
to definition of at least one parameter of at least one of a rule,
a policy and a protocol, wherein the at least one parameter defines
at least one of a configuration for a data collection device, an
access policy for accessing data from the data collection device,
and collection policy for collection of data by the device; and a
policy automation engine for taking the inputs and automatically
configuring and deploying at least one of the rule, the policy and
the protocol within the system for data collection. In embodiments,
the at least one parameter may define at least one of an energy
utilization policy, a cost-based policy, a data writing policy, and
a data storage policy. The parameter may relate to a policy
selected from among compliance, fault, configuration, accounting,
provisioning and security policies for defining how devices are
created, deployed and managed. The compliance policies may include
data ownership policies. The data ownership policies may specify
who owns data. The data ownership policies may specify how owners
may use data. The compliance policies may include data analysis
policies. The data analysis policies may specify what data holders
may access, how data holders may use data, and how data may be
combined with other data by data holders. The compliance policies
may include data use policies, data format policies, and the like.
The data format policies may include standard data format policies,
mandated data format policies. The compliance policies may include
data transmission policies. The data transmission policies may
include inter-jurisdictional transmission data transmission
policies. The compliance policies may include data security
policies, data privacy policies, information sharing policies, and
the like. The data security policies may include at rest data
security policies, transmitted data security policies, and the
like. The information sharing policies may include policies
specifying when information may be sold, when information may be
shared, and the like. The compliance policies may include
jurisdictional policies. The jurisdictional policies may include
policies specifying who controls data. The jurisdictional policies
may include policies specifying when data may be controlled. The
jurisdictional policies may include policies specifying how data
transmitted across boundaries is controlled.
[1804] In embodiments, a policy automation system for a data
collection system in an industrial environment may comprise: a
policy automation engine for enabling configuration of a plurality
of policies applicable to collection and utilization of data
handled by a plurality of network connected devices deployed in a
plurality of industrial environments, wherein the policy automation
engine is hosted on information technology infrastructure elements
that are located separately from the industrial environment,
wherein upon configuration of a policy in the policy automation
engine, the policy is automatically deployed across a plurality of
devices in the plurality of industrial environments, wherein the
policy sets configuration parameters relating to what data is
collected by the data collection system and relating to access
permissions for the collected data. The policies may include a
plurality of policies selected among compliance, fault,
configuration, accounting, provisioning and security policies for
defining how devices are created, deployed and managed, and the
plurality of policies communicatively coupled to policies. A policy
input interface may be structured to receive policy inputs used as
an input to at least one of a rule, policy and protocol definition,
such as where the policy automation system a centralized source of
policies for creating, deploying and managing policies for devices
within an industrial environment.
[1805] In embodiments, a policy automation system for a data
collection system in an industrial environment may comprise: a
policy automation engine for enabling configuration of a plurality
of policies applicable to collection and utilization of data
handled by a plurality of network connected devices deployed in a
plurality of industrial environments, wherein the policy automation
engine is hosted on information technology infrastructure elements
that are located separately from the industrial environment,
wherein upon configuration of a policy in the policy automation
engine, the policy is automatically deployed across a plurality of
devices in the plurality of industrial environments, wherein the
policy sets configuration parameters relating to what data is
collected by the data collection system and relating to access
permissions for the collected data, wherein the policy automation
system is communicatively coupled to a plurality of devices through
a cloud network connection. The cloud network connection may be a
privately-owned cloud connection, a publicly provided cloud
connection, a publicly provided cloud connection, the primary
connection between the policy automation system and device, the
primary connection between the policy automation system and device,
an intranet cloud connection, connecting devices within a single
enterprise, an extranet cloud connection, connecting devices among
multiple enterprises, a secure cloud network connection, secured by
a virtual private network (VPN) connection, and the like.
[1806] In embodiments, a data marketplace for a data collection
system in an industrial environment may comprise: an input
interface structured to receive marketplace inputs; at least one of
a data pool and a data stream to provide collected data within the
marketplace; and data streams that include data from data pools. In
embodiments, at least one parameter of the marketplace may be
automatically configured by a machine learning facility based on a
metric of success of the marketplace. The inputs may include a
plurality of data streams from a plurality of industrial data
collectors. The data collectors may be multiplexing data
collectors. The inputs may include consortia inputs. A consortium
may be an existing consortium, a new consortium, a new consortium
related to a data stream through a common interest, and the like.
The metrics and measures of success may include profit measures,
yield measures, ratings, indicators of interest, and the like. The
ratings may include user ratings, purchaser ratings, licensee
ratings, reviewer ratings, and the like. The indicators of interest
may include clickstream activity, time spent on a page, time spent
reviewing elements, links to data elements, and the like.
[1807] In embodiments, a data marketplace for a data collection
system in an industrial environment may comprise: an input system
structured to receive a plurality of data inputs relating to data
sensed from or about one or more industrial machines; at least one
of a data pool and a data stream to provide collected data within
the marketplace; and a self-organization system for organizing at
least one of the data inputs and the data pools based on a metric
of success of the marketplace. In embodiments, the
self-organization system may optimize variations of the
organization of the data pool over time. The optimized variations
may be based on feedback to one or more measures of success. The
self-organization system may organize how data elements are
presented in the user interface of the marketplace. The
self-organization system may select what data elements are
presented, what data streams are obtained as inputs to the
marketplace, how data elements are described, what metadata is
provided with data elements, a storage method for data elements, a
location within a communication network for the storage elements
(such as in edge elements of a network), a data element combination
method, and the like. A storage method may include a cache or other
"hot" storage method. A storage method may include slower, but less
expensive storage locations. The data element combination method
may be a data fusion method, a data multiplexing method, and the
like. The self-organization system may receive feedback data, such
as where feedback data includes success metrics and measures.
Success metrics and measures may include profit measures, include
yield measures, ratings, indicators of interest, and the like.
Ratings include ratings may be provided by users, purchasers, by
licensees, reviewers. Success metrics and measures may include
indicators of interest. Indicators of interest may include
clickstream activity, time spent on a page activity, time spent
reviewing elements, time spent reviewing elements, links to data
elements, and the like. The self-organization system may determine
the value of data streams. The value of data streams may determine
which data streams are offered for sale by the data marketplace.
The ratings may include user ratings. The ratings may include
purchaser ratings, licensee ratings, reviewer ratings, and the
like.
[1808] In embodiments, a data marketplace for a data collection
system in an industrial environment may comprise: an input
interface structured to receive data inputs from or about one or
more of a plurality of industrial machines; at least one of a data
pool and a data stream to provide collected data within the
marketplace; and a rights management engine for managing
permissions to access the data in the marketplace. In embodiments,
at least one parameter of the rights management engine may be
automatically configured by a machine learning facility based on a
metric of success of the marketplace. The rights management engine
may assign rights to participants of the data marketplace. The
rights may include business strategy and solution rights, liaison
rights, marketing rights, security rights, technology rights,
testbed rights, and the like. The metrics and measures of success
may include profit measures, yield measures, ratings, and the like.
The ratings may include user ratings, purchaser ratings, include
licensee ratings, reviewer ratings, and the like. The metrics and
measures success may include indicators of interest, such as where
interest includes clickstream activity, time spent on a page, time
spent reviewing elements, and links to data elements.
[1809] In embodiments, a data marketplace for a data collection
system in an industrial environment may comprise: an input
interface structured to receive data inputs from or about one or
more of a plurality of industrial machines; at least one of a data
pool and a data stream to provide collected data within the
marketplace; and a data brokering engine configured to execute a
data transaction among at least two marketplace participants. In
embodiments, at least one parameter of the data brokering engine
may be automatically configured by a machine learning facility
based on a metric of success of the marketplace. A data transaction
input may include a marketplace value rating. A marketplace value
rating may be assigned to a marketplace participant. A marketplace
value rating may be assigned to a marketplace participant is
assigned based on the value of input provided by the participant to
the marketplace. A data transaction may be a trade transaction, a
sale transaction, is a payment transaction, and the like. The
metrics and measures of success may include profit measures, yield
measures, ratings, and the like. The ratings may include user
ratings. The ratings may include purchaser ratings, licensee
ratings, reviewer ratings, and the like. The metrics and measures
success may include indicators of interest. The indicators of
interest may include clickstream activity, time spent on a page,
include time spent reviewing elements, links to data elements, and
the like.
[1810] In embodiments, a data marketplace for a data collection
system in an industrial environment may comprise: an input
interface structured to receive data inputs from or about one or
more of a plurality of industrial machines; at least one of a data
pool and a data stream to provide collected data within the
marketplace; and a pricing engine for setting a price for at least
one data element within the marketplace. In embodiments, pricing
may be automatically configured for the pricing engine by a machine
learning facility based on a metric of success of the marketplace.
The metrics and measures of success may include profit measures,
yield measures, include ratings, and the like. The ratings may
include user ratings. The ratings may include purchaser ratings,
licensee ratings, reviewer ratings, and the like. The metrics and
measures success may include indicators of interest. The indicators
of interest may include clickstream activity, time spent on a page,
include time spent reviewing elements, links to data elements, and
the like.
[1811] In embodiments, a data marketplace for a data collection
system in an industrial environment may comprise: an input
interface structured to receive data inputs from or about one or
more of a plurality of industrial machines; at least one of a data
pool and a data stream to provide collected data within the
marketplace; and a user interface for presenting a data element and
at least one mechanism by which a party using the marketplace can
obtain access to the at least one data stream or data pool. In
embodiments, pricing may be automatically configured for the
pricing engine by a machine learning facility based on a metric of
success of the marketplace. The metrics and measures of success may
include profit measures, yield measures, include ratings, and the
like. The ratings may include user ratings. The ratings may include
purchaser ratings, licensee ratings, reviewer ratings, and the
like. The metrics and measures success may include indicators of
interest. The indicators of interest may include clickstream
activity, time spent on a page, include time spent reviewing
elements, links to data elements, and the like.
[1812] In embodiments, a data collection system in an industrial
environment may comprise: a policy automation system for a data
collection system in an industrial environment, comprising: a
plurality of rules selected among roles, permissions and uses, the
plurality of rules communicatively coupled to policies, protocols,
and policy inputs; a plurality of policies selected among
compliance, fault, configuration, accounting, provisioning, and
security policies for defining how devices are created, deployed
and managed, the plurality of policies communicatively coupled to
policies, protocols and policy inputs and a policy input interface
structured to receive policy inputs used as an input to at least
one of a rule, policy and protocol definition.
[1813] In embodiments, a data marketplace may comprise: an input
interface structured to receive marketplace inputs; a plurality of
data pools to store collected data, including marketplace inputs
and make collected data available for use by the marketplace; and
data streams that include data from data pools.
[1814] As described herein and in Appendix B attached hereto,
intelligent industrial equipment and systems may be configured in
various networks, including self-forming networks, private
networks, Internet-based networks, and the like. One or more of the
smart heating systems as described in Appendix B that may
incorporate hydrogen production, storage, and use may be configured
as nodes in such a network. In embodiments, a smart heating system
may be configured with one or more network ports, such as a
wireless network port that facilitate connection through Wi-Fi and
other wired and/or wireless communication protocols as described.
The smart heating system includes a smart hydrogen production
system and a smart hydrogen storage system, and the like described
in Appendix B and may be configured individually or as an integral
system connected as one or more nodes in a network of industrial
equipment and systems. By way of this example, a smart heating
system may be disposed in an on-site industrial equipment
operations center, such as a portable trailer equipped with
communication capabilities and the like. Such deployed smart
heating system may be configured, manually, automatically, or
semi-automatically to join a network of devices, such as industrial
data collection, control, and monitoring nodes and participate in
network management, communication, data collection, data
monitoring, control, and the like.
[1815] In another example of a smart heating system participating
in a network of industrial equipment monitoring, control, and data
collection devices in that a plurality of the smart heating systems
may be configured into a smart heating system sub-network. In
embodiments, data generated by the sub-network of devices may be
communicated over the network of industrial equipment using the
methods and systems described herein.
[1816] In embodiments, the smart heating system may participate in
a network of industrial equipment as described herein. By way of
this example, one or more of the smart heating systems, as depicted
in FIG. 182, may be configured as an IoT device, such as IoT device
13500 and the like described herein. In embodiments, the smart
heating system 13502 may communicate through an access point, over
a mobile ad hoc network or mechanism for connectivity described
herein for devices and systems elements and/or through network
elements described herein.
[1817] In embodiments, one or more smart heating systems described
in Appendix B may incorporate, integrate, use, or connect with
facilities, platforms, modules, and the like that may enable the
smart heating system to perform functions such as analytics,
self-organizing storage, data collection and the like that may
improve data collection, deploy increased intelligence, and the
like. Various data analysis techniques, such as machine pattern
recognition of data, collection, generation, storage, and
communication of fusion data from analog industrial sensors,
multi-sensor data collection and multiplexing, self-organizing data
pools, self-organizing swarm of industrial data collectors, and
others described herein may be embodied in, enabled by, used in
combination with, and derived from data collected by one or more of
the smart heating systems.
[1818] In embodiments, a smart heating system may be configured
with local data collection capabilities for obtaining long blocks
of data (i.e., long duration of data acquisition), such as from a
plurality of sensors, at a single relatively high-sampling rate as
opposed to multiple sets of data taken at different sampling rates.
By way of this example, the local data collection capabilities may
include planning data acquisition routes based on historical
templates and the like. In embodiments, the local data collection
capabilities may include managing data collection bands, such as
bands that define a specific frequency band and at least one of a
group of spectral peaks, true-peak level, crest factor and the
like.
[1819] In embodiments, one or more smart heating systems may
participate as a self-organizing swarm of IoT devices that may
facilitate industrial data collection. The smart heating systems
may organize with other smart heating systems, IoT devices,
industrial data collectors, and the like to organize among
themselves to optimize data collection based on the capabilities
and conditions of the smart heating system and needs to sense,
record, and acquire information from and around the smart heating
systems. In embodiments, one or more smart heating systems may be
configured with processing intelligence and capabilities that may
facilitate coordinating with other members, devices, or the like of
the swarm. In embodiments, a smart heating system member of the
swarm may track information about what other smart heating systems
in a swarm are handling and collecting to facilitate allocating
data collection activities, data storage, data processing and data
publishing among the swarm members.
[1820] In embodiments, a plurality of smart heating systems may be
configured with distinct burners but may share a common hydrogen
production system and/or a common hydrogen storage system. In
embodiments, the plurality of smart heating systems may coordinate
data collection associated with the common hydrogen production
and/or storage systems so that data collection is not unnecessarily
duplicated by multiple smart heating systems. In embodiments, a
smart heating system that may be consuming hydrogen may perform the
hydrogen production and/or storage data collection so that as smart
heating system may prepare to consume hydrogen, they coordinate
with other smart heating systems to ensure that their consumption
is tracked, even if another smart heating system performs the data
collection, handling, and the like. In embodiments, smart heating
systems in a swarm may communicate among each other to determine
which smart heating system will perform hydrogen consumption data
collection and processing when each smart heating system prepares
to stop consumption of hydrogen, such as when heating, cooking, or
other use of the heat is nearing completion and the like. By way of
this example when a plurality of smart heating systems is actively
consuming hydrogen, data collection may be performed by a first
smart heating system, data analytics may be performed by a second
smart heating system, and data and data analytics recording or
reporting may be performed by a third smart heating system. By
allocating certain data collection, processing, storage, and
reporting functions to different smart heating systems, certain
smart heating systems with sufficient storage, processing
bandwidth, communication bandwidth, available energy supply and the
like may be allocated an appropriate role. When a smart heating
system is nearing an end of its heating time, cooking time, or the
like, it may signal to the swarm that it will be going into power
conservation mode soon and, therefore, it may not be allocated to
perform data analysis or the like that would need to be interrupted
by the power conservation mode.
[1821] In embodiments, another benefit of using a swarm of smart
heating systems as disclosed herein is that data storage
capabilities of the swarm may be utilized to store more information
than could be stored on a single smart heating system by sharing
the role of storing data for the swarm.
[1822] In embodiments, the self-organizing swarm of smart heating
systems includes one of the systems being designated as a master
swarm participant that may facilitate decision making regarding the
allocation of resources of the individual smart heating systems in
the swarm for data collection, processing, storage, reporting and
the like activities.
[1823] In embodiments, the methods and systems of self-organizing
swarm of industrial data collectors may include a plurality of
additional functions, capabilities, features, operating modes, and
the like described herein. In embodiments, a smart heating system
may be configured to perform any or all of these additional
features, capabilities, functions, and the like without
limitation.
[1824] The terms "a" or "an," as used herein, are defined as one or
more than one. The term "another," as used herein, is defined as at
least a second or more. The terms "including" and/or "having," as
used herein, are defined as comprising (i.e., open transition).
[1825] While only a few embodiments of the present disclosure have
been shown and described, it will be obvious to those skilled in
the art that many changes and modifications may be made thereunto
without departing from the spirit and scope of the present
disclosure as described in the following claims. All patent
applications and patents, both foreign and domestic, and all other
publications referenced herein are incorporated herein in their
entireties to the full extent permitted by law.
[1826] While only a few embodiments of the present disclosure have
been shown and described, it will be obvious to those skilled in
the art that many changes and modifications may be made thereunto
without departing from the spirit and scope of the present
disclosure as described in the following claims. All patent
applications and patents, both foreign and domestic, and all other
publications referenced herein are incorporated herein in their
entireties to the full extent permitted by law.
[1827] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software,
program codes, and/or instructions on a processor. The present
disclosure may be implemented as a method on the machine, as a
system or apparatus as part of or in relation to the machine, or as
a computer program product embodied in a computer readable medium
executing on one or more of the machines. In embodiments, the
processor may be part of a server, cloud server, client, network
infrastructure, mobile computing platform, stationary computing
platform, or other computing platform. A processor may be any kind
of computational or processing device capable of executing program
instructions, codes, binary instructions, and the like. The
processor may be or may include a signal processor, digital
processor, embedded processor, microprocessor, or any variant such
as a co-processor (math co-processor, graphic co-processor,
communication co-processor, and the like) and the like that may
directly or indirectly facilitate execution of program code or
program instructions stored thereon. In addition, the processor may
enable execution of multiple programs, threads, and codes. The
threads may be executed simultaneously to enhance the performance
of the processor and to facilitate simultaneous operations of the
application. By way of implementation, methods, program codes,
program instructions, and the like described herein may be
implemented in one or more thread. The thread may spawn other
threads that may have assigned priorities associated with them; the
processor may execute these threads based on priority or any other
order based on instructions provided in the program code. The
processor, or any machine utilizing one, may include non-transitory
memory that stores methods, codes, instructions, and programs as
described herein and elsewhere. The processor may access a
non-transitory storage medium through an interface that may store
methods, codes, and instructions as described herein and elsewhere.
The storage medium associated with the processor for storing
methods, programs, codes, program instructions, or other type of
instructions capable of being executed by the computing or
processing device may include but may not be limited to one or more
of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache,
and the like.
[1828] A processor may include one or more cores that may enhance
speed and performance of a multiprocessor. In embodiments, the
process may be a dual core processor, quad core processors, other
chip-level multiprocessor and the like that combine two or more
independent cores (called a die).
[1829] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software
on a server, client, firewall, gateway, hub, router, or other such
computer and/or networking hardware. The software program may be
associated with a server that may include a file server, print
server, domain server, internet server, intranet server, cloud
server, and other variants such as secondary server, host server,
distributed server, and the like. The server may include one or
more of memories, processors, computer readable transitory and/or
non-transitory media, storage media, ports (physical and virtual),
communication devices, and interfaces capable of accessing other
servers, clients, machines, and devices through a wired or a
wireless medium, and the like. The methods, programs, or codes as
described herein and elsewhere may be executed by the server. In
addition, other devices required for execution of methods as
described in this application may be considered as a part of the
infrastructure associated with the server.
[1830] The server may provide an interface to other devices
including, without limitation, clients, other servers, printers,
database servers, print servers, file servers, communication
servers, distributed servers, social networks, and the like.
Additionally, this coupling and/or connection may facilitate remote
execution of program across the network. The networking of some or
all of these devices may facilitate parallel processing of a
program or method at one or more locations without deviating from
the scope of the disclosure. In addition, any of the devices
attached to the server through an interface may include at least
one storage medium capable of storing methods, programs, code,
and/or instructions. A central repository may provide program
instructions to be executed on different devices. In this
implementation, the remote repository may act as a storage medium
for program code, instructions, and programs.
[1831] The software program may be associated with a client that
may include a file client, print client, domain client, internet
client, intranet client, and other variants such as secondary
client, host client, distributed client, and the like. The client
may include one or more of memories, processors, computer readable
transitory and/or non-transitory media, storage media, ports
(physical and virtual), communication devices, and interfaces
capable of accessing other clients, servers, machines, and devices
through a wired or a wireless medium, and the like. The methods,
programs, or codes as described herein and elsewhere may be
executed by the client. In addition, other devices required for
execution of methods as described in this application may be
considered as a part of the infrastructure associated with the
client.
[1832] The client may provide an interface to other devices
including, without limitation, servers, other clients, printers,
database servers, print servers, file servers, communication
servers, distributed servers, and the like. Additionally, this
coupling and/or connection may facilitate remote execution of a
program across the network. The networking of some or all of these
devices may facilitate parallel processing of a program or method
at one or more location without deviating from the scope of the
disclosure. In addition, any of the devices attached to the client
through an interface may include at least one storage medium
capable of storing methods, programs, applications, code, and/or
instructions. A central repository may provide program instructions
to be executed on different devices. In this implementation, the
remote repository may act as a storage medium for program code,
instructions, and programs.
[1833] Various embodiments described in this document relate to
communication protocols that improve aspects of communication
between nodes on a data network. These aspects include, for
instance, average, worst case, or variability in communication
delay, channel utilization, and/or error rate. These embodiments
are primarily described in the context of packet switched networks,
and more particularly in the context of Internet Protocol (IP)
based packet switched networks. However, it should be understood
that at least some of the embodiments are more generally applicable
to data communication that does not use packet switching or IP, for
instance based on circuit-switched of other forms of data
networks.
[1834] Furthermore, various embodiments are described in the
context of data being sent from a "server" to a "client." It should
be understood that these terms are used very broadly, roughly
analogous to "data source" and "data destination". Furthermore, in
at least some applications of the techniques, the nodes are peers,
and may alternate roles as "server" and "client" or may have both
roles (i.e., as data source and data destination) concurrently.
However, for the sake of exposition, examples where there is a
predominant direction of data flow from a "server" node to a
"client" node are described with the understanding that the
techniques described in these examples are applicable to many other
situations.
[1835] One example for a client-server application involves a
server passing multimedia (e.g., video and audio) data, either
recorded or live, to a client for presentation to a user. Improved
aspects of communication from the client to the server in such an
example can reduced communication delay, for instance providing
faster startup, reduced instances of interrupted playback, reduced
instances of bandwidth reduction, and/or increased quality by more
efficient channel utilization (e.g., by avoiding use of link
capacity in retransmissions or unnecessary forward error
correction). This example is useful for exposition of a number of
embodiments. However, it must be recognized that this is merely one
of many possible uses of the approached described below.
[1836] FIG. 183 shows a high-level block diagram of some components
that may be interconnected on a portion of a data network. A
general example of a communication connection or session arranged
on today's Internet may be represented as a client node 125 (e.g.,
a client computer) communicating with a server node 111 (e.g., a
server computer) over one network or an interconnection of multiple
networks 151-152. For example, the client and server nodes may
communicate over the public Internet using the Internet Protocol
(IP). FIG. 183 additionally shows a number of nodes 161, 162
positioned on the respective networks 151, 152, and a client proxy
123 on one of the networks 152.
[1837] Referring to FIG. 184, in an example involving conventional
communication techniques, a client node 125 hosts a client
application 222, which communicates with a TCP module 226 that
implements a Transmission Control Protocol (TCP). The TCP module
226 communicates with an IP module 228 that implements an Internet
Protocol for communicating between nodes on the interconnection of
networks. The communication passes between nodes of the networks
over a channel 230 (i.e., an abstraction of the path comprising
physical links between equipment interconnecting the nodes of the
network). Similarly, the server node 111 hosts a server application
212, a TCP module 216, and an IP module 218. When the server
application 111 and the client application 222 communicate, for
example, with data being passed from the server application to the
client application, TCP module 216 at the server node 111 and the
TCP layer 226 at the client node 125 interact to implement the two
endpoints for the Transmission Control Protocol (TCP).
[1838] Generally, data units 201 (e.g., encoding of multimedia
frames or other units of application data) generated by the server
application 212 are passed to the TCP module 216. The TCP module
assembles data payloads 202, for example, concatenating multiple
data units 201 and/or by dividing data units 201 into multiple data
payloads 202. In the discussion below, these payloads are referred
to in some instances as the "original" or "uncoded" "packets" or
original or uncoded "payloads", which are communicated to the
client (i.e., destination) node in the network. Therefore, it
should be understood that the word "packet" is not used with any
connotation other than being a unit of communication. In the TCP
embodiment illustrated in FIG. 184, each data payload 202 is
"wrapped" in a TCP packet 204, which is passed to the IP module
218, which further wraps the TCP packet 204 in an IP packet 206 for
transmission from the server node 111 to the client node 125, over
what is considered to be a IP layer channel 230 linking the server
node 111 and the client node 125. Note that at lower layers, such
as at a data link layer, further wrapping, unwrapping, and/or
rewrapping of the IP packet 206 may occur, however, such aspects
are not illustrated in FIG. 184. Generally, each payload 202 is
sent in at least one TCP packet 204 and a corresponding IP packet
206, and if not successfully received by the TCP module 226 at the
client node 125, may be retransmitted again by the TCP module 216
at the server node 111 to result in successful delivery. The data
payloads 202 are broken down into the data units 201 originally
provided by the server application 212 and are then delivered in
the same order to the client application 222 as they were provided
by the server application 212.
[1839] TCP implements a variety of features, including
retransmission of lost packets, maintaining order of packets, and
congestion control to avoid congestion at nodes or links along the
path through the network and to provide fair allocation of the
limited bandwidth between and within the networks at intermediate
nodes. For example, TCP implements a "window protocol" in which
only a limited number (or range of sequence numbers) of packets are
permitted to be transmitted for which end-to-end acknowledgments
have not yet been received. Some implementations of TCP adjust the
size of the window, for example, starting initially with a small
window ("slow start") to avoid causing congestion. Some
implementations of TCP also control a rate of transmission of
packets, for example, according to the round-trip-time and the size
of the window.
[1840] The description below details one or more alternatives to
conventional TCP-based communication as illustrated in FIG. 184. In
general, these alternatives improve one or more performance
characteristics, for examples, one or more of overall throughput,
delay, and jitter. In some applications, these performance
characteristics are directly related to application level
performance characteristics, such as image quality in a multimedia
presentation application. Referring to FIG. 183, in a number of
examples, these alternatives are directed to improving
communication between a server node 111 and at least one client
node 125. One example of such communication is streaming media from
the server node 111 to the client nodes 125, however, it should be
recognized that this is only one of many examples where the
described alternatives can be used.
[1841] It should also be understood that the network configuration
illustrated in FIG. 183 is merely representative of a variety of
configurations. A number of these configurations may have paths
with disparate characteristics. For example, a path from the server
node 111 to a client node 125 may pass over links using different
types of equipment and with very different capacities, delays,
error rates, degrees of congestion etc. In many instances, it is
this disparity that presents challenges to achieving end-to-end
communication that achieves high rate, low delay and/or low jitter.
As one example, the client node 125 may be a personal communication
device on a wireless cellular network, the network 152 in FIG. 183
may be a cellular carrier's private wired network, and network 151
may be the public Internet. In another example, the client node 125
may be a "WiFi" node of a private wireless local area network
(WLAN), network 152 may be a private local area network (LAN), and
network 151 may be the public Internet.
[1842] A number of the alternatives to conventional TCP make use of
a Packet Coding (PC) approach. Furthermore, a number of these
approaches make use of Packet Coding essentially at the Transport
Layer. Although different embodiments may have different features,
these implementations are generically referred to below as Packet
Coding Transmission Control Protocol (PC-TCP). Other embodiments
are also described in which the same or similar PC approaches are
used at other layers, for instance, at a data link layer (e.g.,
referred to as PC-DL), and therefore it should be understood that
in general features described in the context of embodiments of
PC-TCP may also be incorporated in PC-DL embodiments.
[1843] Before discussing particular features of PC-TCP in detail, a
number of embodiments of overall system architectures are
described. The later description of various embodiments of PC-TCP
should be understood to be applicable to any of these system
architectures, and others.
Architectures and Applications
Transport Layer Architectures
Kernel Implementation
[1844] Referring to FIG. 185, in one architecture, the TCP modules
at the server node 111 and the client node 125 are replaced with
PC-TCP modules 316 and 326, respectively. Very generally, the
PC-TCP module 316 at the server accepts data units 201 from the
server application 212 and forms original data payloads 202 (i.e.,
"uncoded packets", formed internally to the PC-TCP module 316 and
not illustrated). Very generally, these data payloads 202 are
transported to and/or reconstructed at the PC-TCP module 326 at the
client node 125, where the data units 201 are extracted and
delivered to the client application 222 in the same order as
provided by the server application 212. As described in
substantially more detail below, at least some embodiments of the
PC-TCP modules make use of Random Linear Coding (RLC) for forming
packets 304 for transmission from the source PC-TCP module to the
destination PC-TCP module, with each packet 304 carrying a payload
302, which for at least some packets 304 is formed from a
combination of multiple original payloads 202. In particular, at
least some of the payloads 202 are formed as linear combinations
(e.g., with randomly generated coefficients in a finite field) of
original payloads 202 to implement Forward Error Correction (FEC),
or as part of a retransmission or repair approach in which
sufficient information is not provided using FEC to overcome loss
of packets 304 on the channel 230. Furthermore, the PC-TCP modules
316 and 326 together implement congestion control and/or rate
control to generally coexist in a "fair" manner with other
transport protocols, notably conventional TCP.
[1845] One software implementation of the PC-TCP modules 316 or
326, is software modules that are integrated into the operating
system (e.g., into the "kernel", for instance, of a Unix-based
operating system) in much the same manner that a conventional TCP
module is integrated into the operating system. Alternative
software implementations are discussed below.
[1846] Referring to FIG. 186, in an example in which a client node
125 is a smartphone on a cellular network (e.g., on an LIE network)
and a server node 111 is accessible using IP from the client node,
the approach illustrated in FIG. 185 is used with one end-to-end
PC-TCP session linking the client node 125 and the server node 111.
The IP packets 300 carrying packets 304 of the PC-TCP session
traverse the channel between the nodes using conventional
approaches without requiring any non-conventional handling between
the nodes at the endpoints of the session.
[1847] Alternative Software Implementations
[1848] The description above includes modules generically labeled
"PC-TCP". In the description below, a number of different
implementations of these modules are presented. It should be
understood that, in general, any instance of a PC-TCP module may be
implemented using any of the described or other approaches.
[1849] Referring to FIG. 187, in some embodiments, the PC-TCP
module 326 (or any other instance of PC-TCP module discussed in
this document) is implemented as a PC-TCP module 526, which
includes a Packet Coding (PC) module 525 that is coupled to (i.e.,
communicates with) a convention User Datagram Protocol (UDP) module
524. Essentially each PC-TCP packet described above consists of a
PC packet "wrapped" in a UDP packet. The UDP module 524 then
communicates via the IP modules in a conventional manner. In some
implementations, the PC module 525 is implemented as a "user space"
process, which communicates with a kernel space UDP module, while
in other implementations, the PC module 525 is implement in kernel
space.
[1850] Referring to FIG. 188, in some embodiments, the PC module
625, or its function, is integrated into a client application 622,
which then communicates directly with the conventional UDP module
524. The PC-TCP module 626 therefore effectively spans the client
application 622 and the kernel implementation of the UDP module
524. While use of UDP to link the PC modules at the client and at
the server has certain advantages, other protocols may be used. One
advantage of UDP is that reliable transmission through use of
retransmission is not part of the UDP protocol, and therefore error
handling can be carried out by the PC modules.
[1851] Referring to FIG. 189, in some implementations, a PC-TCP
module 726 is divided into one part, referred to as a PC-TCP "stub"
727, which executes in the kernel space, and another part, referred
to as the PC-TCP "code" 728, which executes in the user space of
the operating system environment. The stub 727 and the code 728
communicate to provide the functionality of the PC-TCP module.
[1852] It should be understood that these software implementations
are not exhaustive. Furthermore, as discussed further below, in
some implementations, a PC-TCP module of any of the architectures
or examples described in this document may be split among multiple
hosts and/or network nodes, for example, using a proxy
architecture.
[1853] Proxy Architectures
[1854] Conventional Proxy Node
[1855] Referring to FIG. 190, certain conventional communication
architectures make use of proxy servers on the communication path
between a client node 125 and a server node 111. For example, a
proxy node 820 hosts a proxy server application 822. The client
application 222 communicates with the proxy server application 822,
which acts as an intermediary in communication with the server
application 212 (not shown in FIG. 190). It should be understood
that a variety of approaches to implementing such a proxy are
known. In some implementations, the proxy application is inserted
on the path without the client node necessarily being aware. In
some implementations, a proxy client 812 is used at the client
node, in some cases forming a software "shim" between the
application layer and the transport layer of the software executing
at the client node, with the proxy client 812 passing communication
to the proxy server application. In a number of proxy approaches,
the client application 222 is aware that the proxy is used, and the
proxy explicitly acts as an intermediary in the communication with
the server application. A particular example of such an approach
makes use of the SOCKS protocol, in which the SOCKS proxy client
application (i.e., an example of the proxy client 812) communicates
with a SOCKS proxy server application (i.e., an example of the
proxy server application 822). The client and server may
communicate over TCP/IP (e.g., via TCP and IP modules 826b and
828b, which may be implemented together in one TCP module), and the
SOCKS proxy server application fulfills communication requests
(i.e., with the server application) on behalf of the client
application (e.g., via TCP and IP modules 826a and 828a). Note that
the proxy server application may also perform functions other than
forwarding communication, for example, providing a cache of data
that can be used to fulfill requests from the client
application.
First Alternative Proxy Node
[1856] Referring to FIG. 191, in an alternative proxy architecture,
a proxy node 920 hosts a proxy server application 922, which is
similar to the proxy server application 822 of FIG. 190. The client
application 222 communicates with the proxy server application 922,
for example as illustrated using conventional TCP/IP, and in some
embodiments using a proxy client 812 (e.g., as SOCKS proxy client),
executing at the client node 125. As illustrated in FIG. 191, the
proxy server application 922 communicates with a server application
using a PC-TCP module 926, which is essentially the same as the
PC-TCP module 326 shown in FIG. 185 for communicating with the
PC-TCP module 316 at the server node 111.
[1857] In some embodiments, the communication architecture of FIG.
191 and the conventional communication architecture of FIG. 184 may
coexist in the communication between the client application and the
server application may use PC-TCP, conventional TCP, or
concurrently use both PC-TCP and TCP. The communication approach
may be based on a configuration of the client application and/or
based on dialog between the client and server applications in
establishing communication between them.
[1858] Referring to FIG. 192, in an example of the architecture
shown in FIG. 191, the proxy application 922 is hosted in a gateway
1020 that links a local area network (LAN) 1050 to the Internet. A
number of conventional client nodes 125a-z are on the LAN, and make
use of the proxy server application to communicate with one or more
server applications over the Internet. Various forms of gateway
1020 may be used, for instance, a router, firewall, modem (e.g.,
cable modem, DSL modem etc.). In such examples, the gateway 1020
may be configured to pass conventional TCP/IP communication between
the client nodes 125a-z and the Internet, and for certain server
applications or under certain conditions (e.g., determined by the
client, the server, or the gateway) use the proxy to make use of
PC-TCP for communication over the Internet.
[1859] It should be understood that the proxy architecture shown in
FIG. 191 may be equally applied to server nodes 111 that
communicate with a proxy node using TCP/IP, with the proxy
providing PC-TCP communication with client nodes, either directly
or via client side proxies. In such cases, the proxy server
application serving the server nodes may be hosted, for instance,
in a gateway device, such as a load balancer (e.g., as might be
used with a server "farm") that links the servers to the Internet.
It should also be understood that in some applications, there is a
proxy node associated with the server node as well as another proxy
associated with the client node.
Integrated Proxy
[1860] Referring to FIG. 193, in some examples, a proxy server
application 1123, which provides essentially the same functionality
as the proxy server application 922 of FIG. 191, is resident on the
client node 1121 rather than being hosted on a separate network
node as illustrated in FIG. 191. In such an example, the connection
between the client application 222 and the proxy server application
1123 is local, with the communication between them not passing over
a data network (although internally it may be passed via the IP
1129 software "stack"). For example, a proxy client 812 (e.g., a
SOCKS client) interacts locally with the proxy server application
1123, or the functions of the proxy client 812 and the proxy server
application 1123 are integrated into a single software
component.
Second Alternative Proxy Node
[1861] In examples of the first alternative proxy node approach
introduced above, communication between the client node and the
proxy node uses conventional techniques (e.g., TCP/IP), while
communication between the proxy node and the server node (or its
proxy) uses PC-TCP 1127. Such an approach may mitigate congestion
and/or packet error or loss on the link between the server node and
the proxy node, however, it would not generally mitigate issues
that arise on the link between the proxy node and the client node.
For example, the client node and the proxy node may be linked by a
wireless channel (e.g., WiFi, cellular, etc.), which may introduce
a greater degree of errors than the link between the server and the
proxy node over a wired network.
[1862] Referring to FIG. 194, in a second proxy approach, the
client node 125 hosts a PC-TCP module 326, or hosts or uses any of
the alternatives of such a module described in this document. The
client application 222 makes use of the PC-TCP module 326 at the
client node to communication with a proxy node 1220. The proxy node
essentially translates between the PC-TCP communication with the
client node 125 and conventional (e.g., TCP) communication with the
server node. The proxy node 1220 includes a proxy server
application 1222, which makes use of a PC-TCP module 1226 to
communicate with the client node (i.e., forms transport layer link
with the PC-TCP module 326) at the client node, and uses a
conventional TCP module 826a to communicate with the server.
[1863] Examples of such a proxy approach are illustrated in FIGS.
195-197. Referring to FIG. 195, an example of a proxy node 1220 is
integrated in a wireless access device 1320 (e.g., a WiFi access
point, router, etc.). The wireless access device 1320 is coupled to
the server via a wired interface 1351 and coupled to a wireless
client node 125 via a wireless interface 1352 at the access device
and a wireless interface 1353 at the client node. The wireless
access device 1320 includes a proxy and communication stack
implementation 1321, which includes the modules illustrated for the
proxy 1220 in FIG. 194, and the wireless client node 125 includes
an application and communication stack implementation 1322, which
includes the modules illustrated for the client node 125 in FIG.
194. Note that the IP packets 300 passing between the access device
1320 and the client node 125 are generally further "wrapped" using
a data layer protocol, for example, in data layer packets 1350. As
introduced above, in some implementations, rather than implementing
the Packet Coding at the transport layer, in a modification of the
approach shown in FIG. 195, the Packet Coding approaches are
implemented at the data link layer.
[1864] Referring to FIG. 196, a proxy node 1220 is integrated in a
node of a private land network of a cellular service provider. In
this example, communication between a server 111 and the proxy node
1220 use conventional techniques (e.g., TCP) over the public
Internet, while communication between the proxy node and the client
node use PC-TCP. It should be understood that the proxy node 1220
can be hosted at various points in the service provider's network,
including without limitation at a gateway or edge device that
connects the provider's private network to the Internet (e.g. a
Packet Data Network Gateway of an LIE network), and/or at an
internal node of the network (e.g., a serving gateway, base station
controller, etc.). Referring to FIG. 197, a similar approach may be
used with a cable television based network. PC-TCP communication
may pass between a head end device and a distribution network
(e.g., a fiber, coaxial, or hybrid fiber-coaxial network) to
individual homes. For example, each home may have devices that
include PC-TCP capabilities themselves, or in some example, a proxy
node (e.g., a proxy node integrated in a gateway 1010 as shown in
FIG. 192) terminates the PC-TCP connections at each home. The proxy
node that communicates with the server 111 using conventional
approaches, while communicating using PC-TCP over the distribution
network is hosted in a node in the service provider's private
network, for instance at a "head end" device 1220b of the
distribution network, or in a gateway device 1220a that links the
service provider's network with the public Internet.
Intermediate Proxy
[1865] Referring to FIG. 198, in another architecture, the channel
between a server node and a client node is broken in to independent
tandem PC-TCP links. An intermediate node 1620 has two instances of
a PC-TCP module 1626 and 1627. One PC-TCP module 1626 terminates a
PC-TCP channel and communicates with a corresponding PC-TCP module
at the server (e.g., hosted at the server node or at a proxy
associated with the server node). The other PC-TCP module 1627
terminates a PC-TCP channel and communicates with a corresponding
PC-TCP module at the client (e.g., hosted at the client node or at
a proxy associated with the client node). The two PC-TCP modules
1626 and 1627 are coupled via a routing application 1622, which
passes decoded data units provided by one of the PC-TCP modules
(e.g., module 1626 from the server node) and to another PC-TCP
module for transmission to the client.
[1866] Note that parameters of the two PC-TCP channels that are
bridged at the intermediate node 1620 do not have to be the same.
For example, the bridged channels may differ in their forward error
correction code rate, block size, congestion window size, pacing
rate, etc. In cases in which a retransmission protocol is used to
address packet errors or losses that are not correctable with
forward error correction coding, the PC-TCP modules at the
intermediate node request or service such retransmission
requests.
[1867] In FIG. 198, only two PC-TCP modules are shown, but it
should be understood that the intermediate node 1620 may
concurrently provide a link between different pairs of server and
client nodes.
[1868] Referring to FIG. 199, an example of this architecture may
involve a server node 111 communicating with an intermediate node
1620, for example, hosted in a gateway device 1720 of a service
provider network with the intermediate node 1620 also communicating
with the client node 125 via a second PC-TCP link.
Recoding Node
[1869] Referring to FIG. 200, another architecture is similar to
the one shown in FIG. 198 in that an intermediate node 1820 is on a
path between a server node 111 and a client node 125, with PC-TCP
communication passing between it and the server node and between it
and the client node.
[1870] In FIG. 198, the PC-TCP modules 1626, 1627 fully decode and
encode the data passing through the node. In the approach
illustrated in FIG. 200, such complete decoding is not necessary.
Rather, a recoding PC-TCP module 1822 receives payloads 1802a-b
from PC-TCP packets 1804a-b, and without decoding to reproduce the
original uncoded payloads 202 (not shown), the module uses the
received PC-TCP packets to send PC-TCP packets 304, with coded
payloads 302, toward the destination. Details of various recoding
approaches are described further later in this document. However,
in general, the processing by the recoding PC-TCP module includes
one or more of the following functions: forwarding PC-TCP packets
without modification to the destination; "dropping" received PC-TCP
packets without forwarding, for example, if the redundancy provided
by the received packets are not needed on the outbound link;
generating and transmitting new PC-TCP packets to provide
redundancy on the outbound link. Note that the recording PC-TCP
module may also provide acknowledgement information on the inbound
PC-TCP link (e.g., without requiring acknowledgement from the
destination node), for example, to the server, and process received
acknowledgements on the outbound link. The processing of the
received acknowledgements may include causing transmission of
additional redundant information in the case that the originally
provided redundancy information was not sufficient for
reconstruction of the payload data.
[1871] In general, the recoding PC-TCP module maintains separate
communication characteristics on the inbound and outbound PC-TCP
channels. Therefore, although it does not decode the payload data,
it does provide control and, in general, the PC-TCP channels may
differ in their forward error correction code rate, block size,
congestion window size, pacing rate, etc.
Multipath Transmission
Single Endpoint Pair
[1872] In examples described above, a single path links the server
node 111 and the client node 125. The possibility of using
conventional TCP concurrently with PC-TCP between two nodes was
introduced. More generally, communication between a pair of PC-TCP
modules (i.e., one at the server node 111 and one at the client
node 125) may follow different paths.
[1873] Internet protocol itself supports packets passing from one
node to another following different paths and possibly being
delivered out of order. Multiple data paths or channels can link a
pair of PC-TCP modules and be used for a single session. Beyond
native multi-path capabilities of IP networks, PC-TCP modules may
use multiple explicit paths for a particular session. For example,
without intending to be exhaustive, combinations of the following
types of paths may be used:
Uncoded TCP and PC over UDP PC over conventional TCP and UDP PC-TCP
over wireless LAN (e.g., WiFi, 802.11) and cellular data (e.g., 3G,
LTE)
[1874] PC-TCP concurrently over multiple wireless base stations
(e.g., via multiple wireless LAN access points)
[1875] In some examples, Network Coding is used such that the
multiple paths from a server node to a client node pass through one
or more intermediate nodes at which the data is recoded, thereby
causing information for different data units to effectively
traverse different paths through the network.
[1876] One motivation for multipath connection between a pair of
endpoints addresses possible preferential treatment of TCP traffic
rather than UDP traffic. Some networks (e.g. certain public Wi-Fi,
cable television networks, etc.) may limit the rate of UDP traffic,
or drop UDP packets preferentially compared to TCP (e.g., in the
case of congestion). It may be desirable to be able to detect such
scenarios efficiently without losing performance. In some
embodiments, a PC-TCP session initially establishes and divides the
transmitted data across both a TCP and a UDP connection. This
allows comparison of the throughput achieved by both connections
while sending distinct useful data on each connection. An
identifier is included in the initial TCP and UDP handshake packets
to identify the two connections as belonging to the same coded
PC-TCP session, and non-blocking connection establishment can be
employed so as to allow both connections to be opened at the outset
without additional delay. The transmitted data is divided across
the two connections using e.g. round-robin (sending alternating
packets or runs of packets on each connection) or
load-balancing/back pressure scheduling (sending each packet to the
connection with the shorter outgoing data queue). Such alternation
or load balancing can be employed in conjunction with techniques
for dealing with packet reordering. Pacing rate and congestion
window size can be controller separately for the UDP and the TCP
connection, or can be controlled together. By controlling the two
connections together (e.g., using only a single congestion window
to regulate the sum of the number of packets in flight on both the
TCP and UDP connections) may provide a greater degree of "fairness"
as compared to separate control.
[1877] In some examples, the adjustment of the fraction of messages
transmitted over each data path/protocol is determined according to
the relative performance/throughput of the data paths/protocols. In
some examples, the adjustment of allocation of messages occurs only
during an initial portion of the transmission. In other examples,
the adjustment of allocation of messages occurs on an ongoing basis
throughout the transmission. In some examples, the adjustment
reverses direction (e.g., when a data path stops preferentially
dropping UDP messages, the number of messages transmitted over that
data path may increase).
[1878] In some embodiments the PC-TCP maintains both the UDP based
traffic and the TCP based traffic for the duration of the session.
In other embodiments, the PC-TCP module compares the behavior of
the UCP and TCP traffic, for example over a period specified in
terms of time interval or number of packets, where these quantities
specifying the period can be set as configuration parameters and/or
modified based on previous coded TCP sessions, e.g. the comparison
period can be reduced or eliminated if information on relative
TCP/UDP performance is available from recent PC-TCP sessions. If
the UDP connection achieves better throughput, the PC-TCP session
can shift to using UDP only. If the TCP connection achieves better
throughput, the PC-TCP session can shift to using TCP. In some
embodiments, different types of traffic are sent over the TCP link
rather than the UDP link. In one such example, the UDP connection
is used to send some forward error correction for packets where it
is beneficial to reduce retransmission delays, e.g. the last block
of a file or intermediate blocks of a stream. In this example, the
uncoded packets may be sent over a TCP stream with forward error
correction packets sent over UDP. If the receiver can use the
forward error correction packets to recover from erasures in the
TCP stream, a modified implementation of the TCP component of the
receiver's PC-TCP module may be able to avoid using a TCP-based
error recovery procedure. On the other hand, non-delivery of a
forward error correction packet does not cause an erasure of the
data that is to be recovered at the receiver, and therefore unless
there is an erasure both on the UDP path and on the TCP path,
dropping of a UDP packet does not cause delay.
Distributed Source
[1879] In some examples, multiple server nodes communicate with a
client node. One way this can be implemented is with there being
multiple communication sessions each involving one server node and
one client node. In such an implementation, there is little or no
interaction between a communication session between one server node
and the client node and another communication session between
another server node and the client node. In some examples, each
server node may have different parts of a multimedia file, with
each server providing its parts for combination at the client
node.
Distributed Content Delivery
[1880] In some examples, there is some relationship between the
content provided by different servers to the client. One example of
such a relationship is use of a distributed RAID approach in which
redundancy information (e.g., parity information) for data units at
one or more servers is stored at and provided from another server.
In this way, should a data unit not reach the client node from one
of the server nodes, the redundancy information may be preemptively
sent or requested from the other node, and the missing data unit
reconstructed.
[1881] In some examples, random linear coding is performed on data
units before they are distributed to multiple server nodes as an
alternative to use of distributed RAID. Then each server node
establishes a separate communication session with the client node
for delivery of part of the coded information. In some of these
examples, the server nodes have content that has already been at
least partially encoded and then cached, thereby avoiding the
necessity of repeating that partial encoding for different client
nodes that will received the same application data units. In some
examples, the server nodes may implement some of the functionality
of the PC modules for execution during communication sessions with
client nodes, for example, having the ability to encode further
redundancy information in response to acknowledgment information
(i.e., negative acknowledgement information) received from a client
node.
[1882] In some implementations, the multiple server nodes are
content delivery nodes to which content is distributed using any of
a variety of known techniques. In other implementations, these
multiple server nodes are intermediary nodes at which content from
previous content delivery sessions was cached and therefore
available without requiring re-delivery of the content from the
ultimate server node.
[1883] In some examples of distributed content delivery, each
server to client connection is substantially independent, for
example, with independently determined communication parameters
(e.g., error correction parameters, congestion window size, pacing
rate, etc.). In other examples, at least some of the parameters are
related, for example, with characteristics determined on one
server-to-client connection being used to determine how the client
node communicates with other server nodes. For example, packet
arrival rate, loss rate, and differences in one-way transmission
rate, may be measured on one connections and these parameters may
be used in optimizing multipath delivery of data involving other
server nodes. One manner of optimization may involve load balancing
across multiple server nodes or over communication links on the
paths from the server nodes to the client nodes.
[1884] In some implementations, content delivery from distributed
server nodes making use of PC-TCP, either using independent
sessions or using coordination between sessions, may achieve the
performance of conventional distributed content delivery but
requiring a smaller number of server nodes. This advantage may
arise due to PC-TCP providing lower latency and/or lower loss rates
than achieved with conventional TCP.
[1885] Multicast
[1886] FIGS. 201-202 show two examples of delivery of common
content to multiple destination nodes simultaneously via multicast
connections. The advantage of multicast is that a single packet or
block of N packets has to be sent by the source node into the
network and the network will attempt to deliver the packets to all
destination nodes in the multicast group. If the content needs to
be delivered reliably, then TCP will most likely be used as the
transport layer protocol. To achieve reliability, TCP requires
destination nodes to respond with acknowledgments and specify the
packets that each destination node is missing. If there are 10s of
thousands or 100s of thousands of receivers, and each destination
node is missing a different packet or set of packets, the number of
different retransmissions to the various receivers will undercut
the advantages of the simultaneous transmission of the content to
all destination nodes at once. With network coding and forward
error correction, a block of N packets can be sent to a large
number of multicast destination nodes at the same time. The paths
to these multiple destination nodes can be similar (all over a
large WiFi or Ethernet local area network) or disparate (some over
WiFi, some over cellular, some over fiber links, and some over
various types of satellite networks). The algorithms described
above that embody transmission and congestion control, forward
error correction, sender based pacing, receiver based pacing,
stream based parameter tuning, detection and correction for missing
and out of order packets, use of information across multiple
connections, fast connection start and stop, TCP/UDP fallback,
cascaded coding, recoding by intermediate nodes, and coding of the
ACKs can be employed to improve the throughput and reliability of
delivery to each of the multicast destination node. When losses are
detected and coding is used, the extra coded packets can be sent to
some or all destination nodes. As long as N packets are received at
each destination node, the missing packets at each destination node
can be reconstructed from the coded packets if the number of extra
coded packets match or exceed the number of packets lost at all of
the receivers. If fewer than N packets are received at any of the
destination nodes, any set of different coded packets from the
block of N packets can be retransmitted and used to reconstruct any
missing packet in the block at each of the destination nodes. If
some destination nodes are missing more than one packet, then the
maximum number of coded packets to be retransmitted will be equal
to the largest number of packets that are missing by any of the
destination nodes. These few different coded packets can be used to
reconstruct the missing packets at each of the destination nodes.
For example if the most packets missing at any destination node is
four, then any four different coded packets can be
retransmitted.
Further Illustrative Examples
[1887] FIGS. 203-213 show exemplary embodiments of data
communication systems and devices and highlight various ways to
implement the novel PC-TCP described herein. These configurations
identify some of the possible network devices, configurations, and
applications that may benefit from using PC-TCP, but there are many
more devices, configurations and applications that may also benefit
from PC-TCP. The following embodiments are described by way of
example, not limitation.
[1888] In an exemplary embodiment depicted in FIG. 203, a user
device 404 such as a smartphone, a tablet, a computer, a
television, a display, an appliance, a vehicle, a home server, a
gaming console, a streaming media box and the like, may include a
PC-TCP proxy that may interface with applications running in the
user device 404. The application on the user device 404 may
communicate with a resource in the cloud 402a such as a server 408.
The server 408 may be a file server, a web server, a video server,
a content server, an application server, a collaboration server, an
FTP server, a list server, a telnet server, a mail server, a proxy
server, a database server, a game server, a sound server, a print
server, an open source server, a virtual server, an edge server, a
storage device and the like, and may include a PC-TCP proxy that
may interface with applications and/or processes running on the
server 408. In embodiments, the server in the cloud may terminate
the PC-TCP connection and interface with an application on the
server 408 and/or may forward the data on to another electronic
device in the network. In embodiments, the data connection may
travel a path that utilizes the resources on a number of networks
402a, 402b. In embodiments PC-TCP may be configured to support
multipath communication such as for example from a video server 408
through a peering point 406, though a carrier network 402b, to a
wireless router or access point 410 to a user device 404 and from a
video server 408 through a peering point 406, though a carrier
network 402b, to a cellular base station or cell transmitter 412 to
a user device 404. In embodiments, the PC-TCP may include
adjustable parameters that may be adjusted to improve multipath
performance. In some instances, the exemplary embodiment shown in
FIG. 203 may be referred to as an over-the-top (OTT)
embodiment.
[1889] In embodiments, such as the exemplary embodiments shown in
FIG. 204 and FIG. 205, other devices in the network may comprise
PC-TCP proxies. For example, the wireless access point or router
410 and the base station or cell transmitter 412 may comprise
PC-TCP proxies. In embodiments, the user device 404 may also
comprise a PC-TCP proxy (FIG. 205) or it may not (FIG. 204). If the
user device does not comprise a PC-TCP proxy, it may communicate
with the access point 410 and/or base station 412 using a wireless
or cellular protocol and/or conventional TCP or UDP protocol. The
PC-TCP proxy in either or both the access point 410 and base
station 412 may receive data packets using these conventional
communications and may convert these communications to the PC-TCP
for a connection to video server 408. In embodiments, if
conventional TCP provides the highest speed connection between the
end user device 404 and/or the access point 410 or the base station
412, then the PC-TCP proxy may utilize only some or all of the
features in PC-TCP that may be compliant with and may compliment
conventional TCP implementations and transmit the data using the
TCP layer.
[1890] FIG. 206 shows an exemplary embodiment where a user device
may comprise a PC-TCP proxy and may communicate with a PC-TCP proxy
server 408 on an internet. In this embodiment, an entity may
provide support for high speed internet connections by renting,
buying services from, or deploying at least one server in the
network and allowing other servers or end user devices to
communicate with it using PC-TCP. The at least one server in the
network running PC-TCP may connect to other resources in the
network and/or end users using TCP or UDP.
[1891] In embodiments, such as the exemplary embodiments shown in
FIG. 207 and FIG. 208, other devices in the network may comprise
PC-TCP proxies. For example, the wireless access point or router
410 and the base station or cell transmitter 412 may comprise
PC-TCP proxies. In embodiments, the user device 404 may also
comprise a PC-TCP proxy (FIG. 208) or it may not (FIG. 207). If the
user device does not comprise a PC-TCP proxy, it may communicate
with the access point 410 and/or base station 412 using a wireless
or cellular protocol and/or conventional TCP or UDP protocol. The
PC-TCP proxy in either or both the access point 410 and base
station 412 may receive data packets using these conventional
communications and may convert these communications to the PC-TCP
for a connection to PC-TCP server 408. In embodiments, if
conventional TCP provides the highest speed connection between the
end user device 404 and/or the access point 410 or the base station
412, then the PC-TCP proxy may utilize only some or all of the
features in PC-TCP that may be compliant with and may compliment
conventional TCP implementations and transmit the data using the
TCP layer.
[1892] In embodiments, at least some network servers 408 may
comprise PC-TCP proxies and may communicate with any PC-TCP servers
or devices using PC-TCP. In other embodiments, network servers may
communicate with PC-TCP servers or devices using conventional TCP
and/or other transport protocols running over UDP.
[1893] In exemplary embodiments as depicted in FIG. 209, ISPs
and/or carriers may host content on one or more servers that
comprise PC-TCP proxies. In embodiments, devices such as set-top
boxes, cable boxes, digital video recorders (DVRs), modems,
televisions, smart televisions, internet televisions, displays, and
the like may comprise PC-TCP proxies. A user device 404 such as
described above, may include a PC-TCP proxy that may interface with
applications running in the user device 404. The application on the
user device 404 may communicate with a resource in the cloud 402c
such as a server 408. The server 408 may be any type of
communications server as describe above, and may include a PC-TCP
proxy that may interface with applications and/or processes running
on the server 408. In embodiments, the server in the cloud may
terminate the PC-TCP connection and interface with an application
on the server 408 and/or may forward the data on to another
electronic device in the network. In embodiments, the data
connection may travel a path that utilizes the resources on a
number of networks 402a, 402b, 402c. In embodiments PC-TCP may be
configured to support multipath communication such as for example
from a video server 408 through a direct peering point (DP) 406, to
a wireless router or access point 410 or a base station 412 to a
user device 404 and from a video server 408 directly to an access
point 410 and/or to a cellular base station or cell transmitter 412
to a user device 404. In embodiments, the PC-TCP may include
adjustable parameters that may be adjusted to improve multipath
performance.
[1894] The exemplary placements of networking devices in the
communication scenarios described above should not be taken as
limitations. It should be recognized that PC-TCP proxies can be
placed in any network device and may support any type of data
connection. That is, any type of end-user device, switching device,
routing device, storage device, processing device and the like, may
comprise PC-TCP proxies. Also PC-TCP proxies may reside only in the
end-nodes of a communication path and/or only at two nodes along a
connection path. However, PC-TCP proxies may also reside in more
than two nodes of a communication path and may support multi-cast
communications and multipath communications. PC-TCP proxies may be
utilized in point-to-point communication networks, multi-hop
networks, meshed networks, broadcast networks, storage networks,
and the like.
[1895] Packet Coding (PC)
[1896] The description above focuses on architectures in which a
packet coding approach is deployed, and in particular architectures
in which a transport layer PC-TCP approach is used. In the
description below, a number of features of PC-TCP are described. It
should be understood that in general, unless otherwise indicated,
these features are compatible with one another and can be combined
in various combinations to address particular applications and
situations.
Data Characteristics
[1897] As introduced above, data units (e.g., audio and/or video
frames) are generally used to form data packets, for example, with
one data unit per data packet, with multiple data units per data
packet, or in some instances separating individual data units into
multiple data packets. In some applications, the data units and
associated data frames form a stream (e.g., a substantially
continuous sequence made available over time without necessarily
having groupings or boundaries in the sequence), while in other
applications, the data units and associated data frames form one or
more batches (e.g., a grouping of data that is required as a whole
by the recipient).
[1898] In general, stream data is generated over time at a source
and consumed at a destination, typically at a substantially steady
rate. An example of a stream is a multimedia stream associated with
person-to-person communication (e.g., a multimedia conference).
Delay (also referred to as latency) and variability in delay (also
referred to as jitter) are important characteristics of the
communication of data units from a source to a destination.
[1899] An extreme example of a batch is delivery of an entire group
of data, for example, a multiple gigabyte sized file. In some such
examples, reducing the overall time to complete delivery (e.g., by
maximizing throughput) of the batch is of primary importance. One
example of batch delivery that may have very sensitive time (and
real-time update) restraints is database replication.
[1900] In some applications, the data forms a series of batches
that require delivery from a source to a destination Although delay
in start of delivery and/or completion of delivery of a batch of
data units may be important, in many applications overall
throughput may be most important. An example of batch delivery
includes delivery of portions of multimedia content, for instance,
with each batch corresponding to sections of viewing time (e.g., 2
seconds of viewing time or 2 MB per batch), with content being
delivered in batches to the destination where the data units in the
batches are buffered and used to construct a continuous
presentation of the content. As a result, an important
consideration is the delivery of the batches in a manner than
provides continuity between batches for presentation, without
"starving" the destination application because a required batch has
not arrived in time. In practice, such starving may cause
"freezing" of video presentation in multimedia, which is a
phenomenon that is all too familiar to today's users of online
multimedia delivery. Another important consideration is reduction
in the initial delay in providing the data units of the first batch
to the destination application. Such delay is manifested, for
example, in a user having to wait for initial startup of video
presentation after selecting multimedia for online delivery.
Another consideration in some applications is overall throughput.
This may arise, for example, if the source application has control
over a data rate of the data units, for example, being able to
provide a higher fidelity version of the multimedia content if
higher throughput can be achieved. Therefore, an important
consideration may be providing a sufficiently high throughput in
order to enable delivery of a high fidelity version of the content
(e.g., as opposed to greatly compressed version or a backed-off
rate of the content resulting in lower fidelity).
[1901] Various packet coding approaches described below, or
selection of configuration parameters of those approaches, address
considerations that are particularly relevant to the nature of the
characteristics of the data being transported. In some examples,
different approaches or parameters are set in a single system based
on a runtime determination of the nature of the characteristics of
the data being transported.
Channel Characteristics
[1902] In general, the communication paths that link PC-TCP source
and destination endpoints exhibit both relatively stationary or
consistent channel characteristics, as well as transient
characteristics. Relatively stationary or consistent channel
characteristics can include, for example, capacity (e.g., maximum
usable throughput), latency (e.g., transit time of packets from
source to destination, variability in transit time), error rate
(e.g., average packet erasure or error rate, burst characteristics
of erasures/errors). In general, such relatively stationary or
consistent characteristics may depend on the nature of the path,
and more particularly on one or more of the links on the path. For
example, a path with a link passing over a 4G cellular channel may
exhibit very different characteristics than a path that passes over
a cable television channel and/or a WiFi link in a home. As
discussed further below, at least some of the approaches to packet
coding attempt to address channel characteristic differences
between types of communication paths. Furthermore, at least some of
the approaches include aspects that track relatively slow variation
in characteristics, for example, adapting to changes in average
throughput, latency, etc.
[1903] Communication characteristics along a path may also exhibit
substantial transient characteristics. Conventional communication
techniques include aspects that address transient characteristics
resulting from congestion along a communication path. It is well
known that as congestion increases, for example at a node along a
communication path, it is important that traffic is reduced at that
node in order to avoid an unstable situation, for instance, with
high packet loss resulting from buffer overruns, which then further
increases data rates due to retransmission approaches. One common
approach to addressing congestion-based transients uses an adaptive
window size of "in flight" packets that have not yet been
acknowledged by their destinations. The size of the window is
adapted at each of the sources to avoid congestion-based
instability, for example, by significantly reducing the size of the
window upon detection of increased packet erasure rates.
[1904] In addressing communication over a variety of channels, it
has been observed that transients in communication characteristics
may not be due solely to conventional congestion effects, and that
conventional congestion avoidance approaches may not be optimal or
even desirable. Some effects that may affect communication
characteristics, and that may therefore warrant adaptation of the
manner in which data is transmitted can include one or more of the
follow:
[1905] Effects resulting from cell handoff in cellular systems,
including interruptions in delivery of packets or substantial
reordering of packets delivered after handoff;
[1906] Effects resulting from "half-duplex" characteristics of
certain wireless channels, for example, in WiFi channels in which
return packets from a destination may be delayed until the wireless
channel is acquired for upstream (i.e., portable device to access
point) communication;
[1907] Effects of explicit data shaping devices, for example,
intended to throttle certain classes of communication, for
instance, based on a service provider's belief that that class of
communication is malicious or is consuming more than a fair share
of resources.
[1908] Although transient effects, which may not be based solely on
congestion, may be tolerated using conventional congestion
avoidance techniques, one or more of the approaches described below
are particularly tailored to such classes of effects with the goal
of maintaining efficient use of a channel without undue
"over-reaction" upon detection of a transient situation, while
still avoiding causing congestion-based packet loss.
Inter-Packet Coding
[1909] In general, the coding approaches used in embodiments
described in this document make use of inter-packet coding in which
redundancy information is sent over the channel such that the
redundancy information in one packet is generally dependent on a
set of other packets that have been or will be sent over the
channel. Typically, for a set of N packets of information, a total
of N+K packets are sent in a manner that erasure or any K of the
packets allows reconstruction of the original N packets of
information. In general, a group of N information packets, or a
group of N+K packets including redundancy information (depending on
context), is referred to below as a "block" or a "coding block".
One example of such a coding includes N information packets without
further coding, and then K redundancy packets, each of which
depends on the N information packets. However it should be
understood more than K of the packets (e.g., each of the N+K
packets) may in some embodiments depend on all the N information
packets.
Forward Error Correction and Repair Retransmission
[1910] Inter-packet coding in various embodiments described in this
document use one or both of pre-emptive transmission of redundant
packets, generally referred to as forward error correction (FEC),
and transmission of redundant packets upon an indication that
packets have or have a high probability of having been erased based
on feedback, which is referred to below as repair and/or
retransmission. The feedback for repair retransmission generally
comes from the receiver, but more generally may come from a node or
other channel element on the path to the receiver, or some network
element having information about the delivery of packets along the
path. In the FEC mode, K redundant packets may be transmitted in
order to be tolerant of up to K erasures of the N packets, while in
the repair mode, in some examples, for each packet that the
transmitter believes has been or has high probability of having
been erased, a redundant packet it transmitted from the
transmitter, such that if in a block of N packets, K packets are
believed to have been erased based on feedback, the transmitter
sends at least an additional K packets.
[1911] As discussed more fully below, use of a forward error
correction mode versus a repair mode represents a tradeoff between
use of more channel capacity for forward error correction (i.e.,
reduced throughout of information) versus incurring greater latency
in the presence of erasures for repair retransmission. As
introduced above, the data characteristics being transmitted may
determine the relative importance of throughput versus latency, and
the PC-TCP modules may be configured or adapted accordingly.
[1912] If on average the packet erasure rate E is less than
K/(N+K), then "on average" the N+K packets will experience erasure
of K or fewer of the packets and the remaining packets will be
sufficient to reconstruct the original N. Of course even if E is
not greater than K/(N+K), random variability, non-stationarity of
the pattern of erasures etc. results in some fraction of the sets
of N+K packets having greater than K erasures, so that there is
insufficient information to reconstruct the N packets at the
destination. Therefore, even using FEC, at least some groups of N
information packets will not be reconstructable. Note, for example,
with E=0.2, N=8, and K=2, even though only 2 erasures may be
expected on average, the probability of more than 2 erasures is
greater than 30%, and even with E=0.1 this probability is greater
than 7%, therefore the nature (e.g., timing, triggering conditions
etc.) of the retransmission approaches may be significant, as
discussed further below. Also as discussed below, the size of the
set of packets that are coded together is significant. For example,
increasing N by a factor of 10 to K+N=100 reduces the probably of
more than the average number of 20 erasures (i.e., too many
erasures to reconstruct the N=80 data packets) from over 7% to less
than 0.1%.
[1913] Also as discussed further below, there is a tradeoff between
use of large blocks of packets (i.e., large N) versus smaller
blocks. For a particular code rate R=N/(N+K), longer blocks yield a
higher probability of being able to fully recover the N information
packets in the presence of random errors. Accordingly, depending on
the data characteristics, the PC-TCP modules may be configured to
adapt to achieve a desired tradeoff.
[1914] In general, in embodiments that guarantee delivery of the N
packets, whether or not FEC is used, repair retransmission
approaches are used to provide further information for
reconstructing the N packets. In general, in preferred embodiments,
the redundancy information is formed in such a manner that upon an
erasure of a packet, the redundancy information that is sent from
the transmitter does not depend on the specific packets that were
erased, and is nevertheless suitable for repairing the erasure
independent of which packet was erased.
[1915] Random Linear Coding
[1916] In general, a preferred approach to inter-packet coding is
based on Random Linear Network Coding (RLNC) techniques. However,
it should be understood that although based on this technology, not
all features that may be associated with this term are necessarily
incorporated. In particular, as described above in the absence of
intermediate nodes that perform recoding, there is not necessarily
a "network" aspect to the approach. Rather, redundancy information
is generally formed by combining the information packets into coded
packets using arithmetic combinations, and more specifically, as
sums of products of coefficients and representation of the
information packets over arithmetic fields, such as finite fields
(e.g., Galois Fields of order p.sup.n). In general, the code
coefficients are chosen from a sufficiently large finite field in a
random or pseudo-random manner, or in another way that the
combinations of packets have a very low probability or frequency of
being linearly dependent. The code coefficients, or a compressed
version (e.g., as a reference into a table shared by the
transmitter and receiver), are included in each transmitted
combination of data units (or otherwise communicated to the
receiver) and used for decoding at the receiver. Very generally,
the original information packets may be recovered at a receiver by
inverting the arithmetic combinations. For example, a version of
Gaussian Elimination may be used to reconstruct the original
packets from the coded combinations. A key feature of this approach
is that for a set of N information packets, as soon at the receiver
has at least N linearly independent combinations of those
information packets in received packets, it can reconstruct the
original data units. The term "degree of freedom" is generally used
below to refer to a number of independent linear combinations, such
that if N degrees of freedom have been specified for N original
packets, then the N original packets can be reconstructed; while if
fewer than N degrees of freedom are available, it may not be
possible to fully reconstruct any of the N original packets. If N+K
linearly independent linear combinations are sent, then any N
received combinations (i.e., N received degrees of freedom) are
sufficient to reconstruct the original information packets.
[1917] In some examples, the N+K linearly independent combinations
comprise N selections of the N "uncoded" information packets
(essentially N-1 zero coefficients and one unit coefficient for
each uncoded packet), and K coded packets comprising the random
arithmetic combination with N non-zero coefficients for the N
information packets. The N uncoded packets are transmitted first,
so that in the absence of erasures they should be completely
received as soon as possible. In the case of one erasure of the
original N packets, the receiver must wait for the arrival of one
redundant packet (in addition to the N-1 original packets), and
once that packet has arrived, the erased packet may be
reconstructed. In the case of forward error correction, the K
redundant packets follow (e.g., immediately after) the information
packets, and the delay incurred in reconstructing the erased
information packet depends on the transmission time of packets. In
the case of repair retransmission, upon detection of an erasure or
high probability of an erasure, the receiver provides feedback to
the transmitter, which sends the redundancy information upon
receiving the feedback. Therefore, the delay in being able to
reconstruct the erased packet depends on the round-trip-time from
the receiver to the transmitter and back.
[1918] As discussed in more detail below, feedback from the
receiver to the transmitter may be in the form of acknowledgments
sent from the receiver to the transmitter. This feedback in
acknowledgements at least informs the transmitter of a number of
the N+K packets of a block that have been successfully received
(i.e., the number of received degrees of freedom), and may provide
further information that depends on the specific packets that have
been received at the receiver although such further information is
not essential.
[1919] As introduced above, packets that include the combinations
of original packets generally also include information needed to
determine the coefficients used to combine the original packets,
and information needed to identify which original packets were used
in the combination (unless this set, such as all the packets of a
block, is implicit). In some implementations, the coefficients are
explicitly represented in the coded packets. In some embodiments,
the coefficients are encoded with reference to shared information
at the transmitter and the receiver. For instance, tables of
pre-generated (e.g., random, pseudo random, or otherwise selected)
coefficients, or sets of coefficients, may be stored and references
into those tables are used to determine the values of the
coefficients. The size of such a table determines the number of
parity packets that can be generated while maintaining the linear
independence of the sets of coefficients. It should be understood
that yet other ways may be used to determine the coefficients.
[1920] Another feature of random linear codes is that packets
formed as linear combinations of data units may themselves be
additively combined to yield combined linear combinations of data
units. This process is referred to in some instances as "recoding",
as distinct from decoding and then repeating encoding.
[1921] There are alternatives to the use of RLNC, which do not
necessarily achieve similar optimal (or provably optimum, or near
optimal) throughput as RLNC, but that give excellent performance in
some scenarios when implemented as described herein. For example,
various forms of parity check codes can be used. Therefore, it
should be understood that RLNC, or any particular aspect of RLNC,
is not an essential feature of all embodiments described in this
document.
Batch Transmission
[1922] As introduced above, in at least some applications, data to
be transmitted from a transmitter to a receiver forms a batch
(i.e., as opposed to a continuous stream), with an example of a
batch being a file or a segment (e.g., a two second segment of
multimedia) of a file.
[1923] In an embodiment of the PC-TCP modules, the batch is
transferred from the transmitter to the receiver as a series of
blocks, with each block being formed from a series of information
packets. In general, each block has the same number of information
packets, however use of same size blocks is not essential.
[1924] The transmitter PC-TCP module generally receives the data
units from the source application and forms the information packets
of the successive blocks of the batch. These information packets
are queued at the transmitter and transmitted on the channel to the
receiver. In general, at the transmitter, the dequeueing and
transmission of packets to the receiver makes use of congestion
control and/or rate control mechanisms described in more detail
below. The transmitter PC-TCP also retains the information packets
(or sufficient equivalent information) to construct redundancy
information for the blocks. For instance the transmitter PC-TCP
buffers the information packets for each block for which there
remains the possibility of an unrecovered erasure of a packet
during transit from the transmitter to the receiver.
[1925] In general, the receiver provides feedback to the
transmitter. Various approaches to determining when to provide the
feedback and what information to provide with the feedback are
described further below. The feedback provides the transmitter with
sufficient information to determine that a block has been
successfully received and/or reconstructed at the receiver. When
such success feedback for a block has been received, the
transmitter no longer needs to retain the information packets for
the block because there is no longer the possibility that
redundancy information for the block will need to be sent to the
receiver.
[1926] The feedback from the receiver to the transmitter may also
indicate that a packet is missing. Although in some cases the
indication that a packet is missing is a premature indication of an
erasure, in this embodiment the transmitter uses this missing
feedback to trigger sending redundant information for a block. In
some examples, the packets for a block are numbered in sequence of
transmission, and the feedback represents the highest number
received and the number of packets (i.e., the number of degrees of
freedom) received (or equivalently the number of missing packets or
remaining degrees of freedom needed) for the block. The transmitter
addresses missing packet feedback for a block through the
transmission of redundant repair blocks, which may be used by the
receiver to reconstruct the missing packets and/or original packets
of the block.
[1927] As introduced above, for each block, the transmitter
maintains sufficient information to determine the highest index of
a packet received at the receiver, the number of missing packets
transmitted prior to that packet, and the number of original or
redundancy packets after the highest index received that have been
transmitted (i.e., are "in flight" unless erased in transit) or
queued for transmission at the transmitter.
[1928] When the transmitter receives missing packet feedback for a
block, if the number of packets for the block that are "in flight"
or queue would not be sufficient if received successfully (or are
not expected to be in view of the erasure rate), the transmitter
computes (or retrieves precomputed) a new redundant packet for the
block and queues it for transmission. Such redundancy packets are
referred to as repair packets. In order to reduce the delay in
reconstructing a block of packets at the receiver, the repair
packets are sent preferentially to the information packets for
later blocks. For instance, the repair packets are queued in a
separate higher-priority queue that is used to ensure transmission
of repair packets preferentially to the queue of information
packets.
[1929] In some situations, feedback from the receiver may have
indicated that a packet is missing. However, that packet may later
arrive out of order, and therefore a redundant packet for that
block that was earlier computed and queued for transmission is no
longer required to be delivered to the receiver. If that redundant
packet has not yet been transmitted (i.e., it is still queued),
that packet may be removed from the queue thereby avoiding wasted
use of channel capacity for a packet that will not serve to pass
new information to the receiver.
[1930] In the approach described above, redundancy packets are sent
as repair packets in response to feedback from the receiver. In
some examples, some redundancy packets are sent pre-emptively
(i.e., as forward error correction) in order to address possible
packet erasures. One approach to send such forward error correction
packets for each block. However, if feedback has already been
received at the transmitter that a sufficient number of original
and/or coded packets for a block have been received, then there is
no need to send further redundant packets for the block.
[1931] In an implementation of this approach, the original packets
for all the blocks of the batch are sent first, while repair
packets are being preferentially sent based on feedback from the
receiver. After all the original packets have been transmitted, and
the queue of repair packets is empty, the transmitter computes (or
retrieves precomputed) redundancy packets for blocks for which the
transmitter has not yet received feedback that the blocks have been
successfully received, and queues those blocks as forward error
correction packets for transmission in the first queue. In general,
because the repair blocks are sent with higher priority that the
original packets, the blocks for which success feedback has not yet
been received are the later blocks in the batch (e.g., a trailing
sequence of blocks of the batch).
[1932] In various versions of this approach, the number and order
of transmission of the forward error correction packets are
determined in various ways. A first way uses the erasure rate to
determine how many redundant packets to transmit. One approach is
to send at least one redundant packet for each outstanding block.
Another approach is to send a number of redundancy packets for each
outstanding block so that based on an expectation of the erasure
rate of the packets that are queued and in flight for the block
will yield a sufficient number of successfully received packets in
order to reconstruct the block. For example, if a further n packets
are needed to reconstruct a block (e.g., a number n<N packets of
the original N packets with N-n packets having been erased), then
n+k packets are sent, for instance, with n+k.gtoreq.n/E, where E is
an estimate of the erasure rate on the channel.
[1933] Another way of determining the number and order of forward
error correction packets addresses the situation in which a block
transmission time is substantially less than the round-trip-time
for the channel. Therefore, the earliest of the blocks for which
the transmitter has not received success feedback may in fact have
the success feedback in flight from the receiver to the
transmitter, and therefore sending forward error correction packets
may be wasteful. Similarly, even if feedback indicating missing
packet feedback for a block is received sufficiently early, the
transmitter may still send a repair packet without incurring more
delay in complete reconstruction of the entire batch than would be
achieved by forward error correction.
[1934] In an example, the number of forward error correction
packets queued for each block is greater for later blocks in the
batch than for earlier ones. A motivation for this can be
understood by considering the last block of the batch where it
should be evident that it is desirable to send a sufficient number
of forward error correction packets to ensure high probability of
the receiver having sufficient information to reconstruct the block
without the need from transmission of a repair packet and the
associated increase in latency. On the other hand, it is preferable
to send fewer forward error correction packets for the previous (or
earlier) block because in the face of missing packet feedback from
the receiver, the transmitter may be able to send a repair packet
before forward error correction packets for all the later blocks
have been sent, thereby not incurring a delay in overall delivery
of the batch.
[1935] In one implementation, after all the original packets have
been sent, and the transmitter is in the forward error correction
phase in which it computes and sends the forward error correction
packets, if the transmitter receives a missing packet feedback from
the receiver, it computes and sends a repair packet for the block
in question (if necessary) as described above, and clears the
entire queue of forward error correction packets. After the repair
packet queue is again empty, the transmitter again computes and
queues forward error correction packets for the blocks for which it
has not yet received success feedback. In an alternative somewhat
equivalent implementation, rather than clearing the forward error
correction queue upon receipt of a missing packet feedback, the
transmitter removes forward error correction packets from the queue
as they are no longer needed based on feedback from the receiver.
In some examples, if success feedback is received for a block for
which there are queued forward error correction packets, those
forward error correction packets are removed from the queue. In
some examples, the feedback from the receiver may indicate that
some but not all of the forward error correction packets in the
queue are no longer needed, for example, because out-of-order
packets were received but at least some of the original packets are
still missing.
[1936] An example of the way the transmitter determines how many
forward error correction packets to send is that the transmitter
performs a computation:
(N+g(i)-a.sub.i)/(1-p)-f.sub.i
where
[1937] p=smoothed loss rate,
[1938] N=block size,
[1939] i=block index defined as number of blocks from last
block,
[1940] a.sub.i=number of packets asked from block i,
[1941] f.sub.i=packets in-flight from block i, and
[1942] g(i)=a decreasing function of i,
to determine the number of FEC packets for a block.
[1943] In some examples, g(i) is determined as a maximum of a
configurable parameter, m and N-i. In some examples, g(i) is
determined as N-p(i) where p is a polynomial, with integer rounding
as needed
[1944] It should be understood that in some alternative
implementations, at least some forward error correction packets may
be interspersed with the original packets. For example, if the
erasure rate for the channel is relatively high, then at least some
number of redundancy packets may be needed with relatively high
probability for each block, and there is an overall advantage to
preemptively sending redundant FEC packets as soon as possible, in
addition to providing the mechanism for feedback based repair that
is described above.
[1945] It should be also understood that use of subdivision of a
batch into blocks is not necessarily required in order to achieve
the goal of minimizing the time to complete reconstruction of the
block at the receiver. However, if the forward error correction is
applied uniformly to all the packets of the batch, then the
preferential protection of later packets would be absent, and
therefore, latency caused by erasure of later packets may be
greater than using the approach described above. However,
alternative approaches to non-uniform forward error protection
(i.e., introduction of forward error correction redundancy packets)
may be used. For example, in the block based approach described
above, packets of the later blocks each contribute to a greater
number of forward error correction packets than do earlier ones,
and an alternative approach to achieving this characteristic maybe
to use a non-block based criterion to construction of the
redundancy packets in the forward error correction phase. However,
the block based approach described above has advantages of relative
simplicity and general robustness, and therefore even if marginally
"suboptimal" provides an overall advantageous technical solution to
minimizing the time to complete reconstruction within the
constraint of throughput and erasure on the channel linking the
transmitter and receiver.
[1946] Another advantage of using a block-based approach is that,
for example, when a block within the batch, say the m.sup.th block
of M blocks of the batch has an erasure, the repair packet that is
sent from the transmitter depends only on the N original packets of
the m.sup.th block. Therefore, as soon as the repair packet
arrives, and the available (i.e., not erased) N-1 packets of the
block arrive, the receiver has the information necessary to repair
the block. Therefore, by constructing the repair packet without
contribution of packets in later blocks of the batch, the latency
of the reconstruction of the block is reduced. Furthermore, by
having the repair packets depend on only N original packets, the
computation required to reconstruct the packets of the block is
less than if the repair packets depend on more packets.
[1947] It should be understood that even in the block based
transmission of a batch of packets, the blocks are not necessarily
uniform in size, and are not necessarily disjoint. For example,
blocks may overlap (e.g., by 50%, 75%, etc.) thereby maintaining at
least some of the advantages of reduced complexity in
reconstruction and reduced buffering requirements as compared to
treating the batch as one block. An advantage of such overlapping
blocks may be a reduced latency in reconstruction because repair
packets may be sent that do not require waiting for original
packets at the receiver prior to reconstruction. Furthermore,
non-uniform blocks may be beneficial, for example, to increase the
effectiveness of forward error correction for later block in a
batch by using longer blocks near the end of a batch as compared to
near the beginning of a batch.
[1948] In applications in which the entire batch is needed by the
destination application before use, low latency of reconstruction
may be desirable to reduce buffering requirements in the PC-TCP
module at the receiver (and at the transmitter). For example, all
packets that may contribute to a later received repair packet are
buffered for their potential future use. In the block based
approach, once a block is fully reconstructed, then the PC-TCP
module can deliver and discard those packets because they will not
affect future packet reconstruction.
[1949] Although described as an approach to delivery of a batch of
packets, the formation of these batches may be internal to the
PC-TCP modules, whether or not such batches are formed at the
software application level. For example, the PC-TCP module at the
transmitter may receive the original data units that are used to
form the original packets via a software interface from the source
application. The packets are segmented into blocks of N packets as
described above, and the packets queued for transmission. In one
embodiment, as long as the source application provides data units
sufficiently quickly to keep the queue from emptying (or from
emptying for a threshold amount of time), the PC-TCP module stays
in the first mode (i.e., prior to sending forward error correction
packets) sending repair packets as needed based on feedback
information from the receiver. When there is a lull in the source
application providing data units, then the PC-TCP module declares
that a batch has been completed, and enters the forward error
correction phase described above. In some examples, the batch
formed by the PC-TCP module may in fact correspond to a batch of
data units generated by the source application as a result of a
lull in the source application providing data units to the PC-TCP
module while it computes data units for a next batch, thereby
inherently synchronizing the batch processing by the source
application and the PC-TCP modules.
[1950] In one such embodiment, the PC-TCP module remains in the
forward error correction mode for the declared batch until that
entire batch has been successfully reconstructed at the receiver.
In another embodiment, if the source application begins providing
new data units before the receiver has provided feedback that the
previous batch has been successfully reconstructed, the transmitter
PC-TCP module begins sending original packets for the next batch at
a lower priority than repair or forward error correction packets
for the previous batch. Such an embodiment may reduce the time to
the beginning of transmission of the next batch, and therefore
reduces the time to successful delivery of the next batch.
[1951] In the embodiments in which the source application does not
necessarily provide the data in explicit batches, the receiver
PC-TCP module provides the data units in order to the destination
application without necessarily identifying the block or batch
boundaries introduced at the transmitter PC-TCP module. That is, in
at least some implementations, the transmitter and receiver PC-TCP
modules provide a reliable channel for the application data units
without exposing the block and batch structure to the
applications.
[1952] As described above for certain embodiments, the transmitter
PC-TCP module reacts to missing packet feedback from the receiver
PC-TCP module to send repair packets. Therefore, it should be
evident that the mechanism by which the receiver sends such
feedback may affect the overall behavior of the protocol. For
example, in one example, the receiver PC-TCP module sends a
negative acknowledgment as soon as it observes a missing packet.
Such an approach may provide the lowest latency for reconstruction
of the block. However, as introduced above, missing packets may be
the result of out-of-order delivery. Therefore, a less aggressive
generation of missing packet feedback, for example, by delay in
transmission of a negative acknowledgment, may reduce the
transmission of unnecessary repair packets with only a minimal
increase in latency in reconstruction of that block. However, such
delay in sending negative acknowledgements may have an overall
positive impact on the time to successfully reconstruct the entire
block because later blocks are not delayed by unnecessary repair
packets. Alternative approaches to generation of acknowledgments
are described below.
[1953] In some embodiments, at least some of the determination of
when to send repair packets is performed at the transmitter PC-TCP.
For example, the receiver PC-TCP module may not delay the
transmission of missing packet feedback, and it is the transmitter
PC-TCP module that delays the transmission of a repair packet based
on its weighing of the possibility of the missing packet feedback
being based on out-of-order delivery as opposed to erasure.
[1954] Protocol Parameters
[1955] Communication between two PC-TCP endpoints operates
according to parameters, some of which are maintained in common by
the endpoints, and some of which are local to the sending and/or
the receiving endpoint. Some of these parameters relate primarily
to forward error correction aspects of the operation. For example,
such parameters include the degree of redundancy that is introduced
through the coding process. As discussed below, further parameters
related to such coding relate to the selection of packets for use
in the combinations. A simple example of such selection is
segmentation of the sequence of input data units into "frames" that
are then independently encoded. In addition to the number of such
packets for combination (e.g., frame length), other parameters may
relate to overlapping and/or interleaving of such frames of data
units and/or linear combinations of such data units.
[1956] Further parameters relate generally to transport layer
characteristics of the communication approach. For example, some
parameters relate to congestion avoidance, for example,
representing a size of a window of unacknowledged packets,
transmission rate, or other characteristics related to the timing
or number of packets sent from the sender to the receiver of the
PC-TCP communication.
[1957] As discussed further below, communication parameters (e.g.,
coding parameters, transport parameters) may be set in various
ways. For example, parameters may be initialized upon establishing
a session between two PC-TCP endpoints. Strategies for setting
those parameters may be based on various sources of information,
for example, according to knowledge of the communication path
linking the sender and receiver (e.g., according to a
classification of path type, such as 3G wireless versus cable
modem), or experienced communication characteristics in other
sessions (e.g., concurrent or prior sessions involving the same
sender, receiver, communication links, intermediate nodes, etc.).
Communication parameters may be adapted during the course of a
communication session, for example, in response to observed
communication characteristics (e.g., congestion, packet loss,
round-trip time, etc.) Transmission control
[1958] Some aspects of the PC-TCP approaches relate to control of
transmission of packets from a sender to a receiver. These aspects
are generally separate from aspects of the approach that determine
what is sent in the packets, for example, to accomplish forward
error correction, retransmission, or the order in which the packets
are sent (e.g., relative priority of forward error correction
packets version retransmission packets). Given a queue of packets
that are ready for transmission from the sender to the receiver,
these transmission aspects generally relate to flow and/or
congestion control.
Congestion Control
[1959] Current variants of TCP, including binary increase
congestion control (BIC) and cubic-TCP, have been proposed to
address the inefficiencies of classical TCP in networks with high
losses, large bandwidths and long round-trip times. BIC-TCP and
CUBIC algorithms have been used because of their stability. After a
backoff, BIC increases the congestion window linearly then
logarithmically to the window size just before backoff (denoted by
W.sub.max) and subsequently increases the window in an
anti-symmetric fashion exponentially then linearly. CUBIC increases
the congestion window following backoff according to a cubic
function with inflection point at W.sub.max. These increase
functions cause the congestion window to grow slowly when it is
close to W.sub.max, promoting stability. On the other hand, other
variants such as HTCP and FAST TCP have the advantage of being able
to partially distinguish congestion and non-congestion losses
through the use of delay as a congestion signal.
[1960] An alternative congestion control approach is used in at
least some embodiments. In some such embodiments, we identify a
concave portion of the window increase function as
W.sub.concave(t)+W.sub.max+c.sub.1(t-k).sup.3 and a convex portion
of the window increase function as
W.sub.convex(t)=W.sub.nax+c.sub.2 (t-k).sup.3 where c.sub.1 and
c.sub.2 are positive tunable parameters and
k = ( ( W_max - W ) / c 1 ) 3 ##EQU00001##
and W is the window size just after backoff.
[1961] This alternative congestion control approach can be flexibly
tuned for different scenarios. For example, a larger value of
c.sub.1 causes the congestion window to increase more rapidly up to
W.sub.max and a large value of c.sub.2 causes the congestion window
to increase more rapidly beyond W.sub.max.
[1962] Optionally, delay is used as an indicator to exit slow start
and move to the more conservative congestion avoidance phase, e.g.
when a smoothed estimate of RTT exceeds a configured threshold
relative to the minimum observed RTT for the connection. We can
also optionally combine the increase function of CUBIC or other TCP
variants with the delay-based backoff function of HTCP.
[1963] In some embodiments, backoff is smoothed by allowing a lower
rate of transmission until the number of packets in flight
decreases to the new window size. For instance, a threshold, n, is
set such that once n packets have been acknowledged following a
backoff, then one packet is allowed to be sent for every two
acknowledged packets, which is roughly half of the previous sending
rate. This is akin to a hybrid window and rate control scheme.
Transmission Rate Control
Pacing Control by Sender
[1964] In at least some embodiments, pacing is used to regulate
and/or spread out packet transmissions, making the transmission
rate less bursty. While pacing can help to reduce packet loss from
buffer overflows, previous implementations of pacing algorithms
have not shown clear advantages when comparing paced TCP
implementations to non-paced TCP implementations. However, in
embodiments where the data packets are coded packets as described
above, the combination of packet coding and pacing may have
advantages. For example, since one coded packet may be used to
recover multiple possible lost packets, we can use coding to more
efficiently recover from any spread out packet losses that may
result from pacing. In embodiments, the combination of packet
coding and pacing may have advantages compared to uncoded TCP with
selective acknowledgements (SACK).
[1965] Classical TCP implements end-to-end congestion control based
on acknowledgments. Variants of TCP designed for high-bandwidth
connections increase the congestion window (and consequently the
sending rate) quickly to probe for available bandwidth but this can
result in bursts of packet losses when it overshoots, if there is
insufficient buffering in the network.
[1966] A number of variants of TCP use acknowledgment feedback to
determine round-trip time and/or estimate available bandwidth, and
they differ in the mechanisms with which this information is used
to control the congestion window and/or sending rate. Different
variants have scenarios in which they work better or worse than
others.
[1967] In one general approach used in one or more embodiments, a
communication protocol may use smoothed statistics of intervals
between acknowledgments of transmitted packets (e.g., a smoothed
"ack interval") to guide a transmission of packets, for example, by
controlling intervals (e.g., an average interval or equivalently an
average transmission rate) between packet transmissions. Broadly,
this guiding of transmission intervals is referred to herein as
"pacing".
[1968] In some examples, the pacing approach is used in conjunction
with a window-based congestion control algorithm. Generally, the
congestion window controls the number of unacknowledged packets
that can be sent, in some examples using window control approaches
that are the same or similar to those used in known variants of the
Transmission Control Protocol (TCP). In embodiments, the window
control approach is based on the novel congestion control
algorithms described herein.
[1969] A general advantage of one or more aspects is to improve
functioning of a communication system, for instance, as measured by
total throughput, or delay and/or variation in delay. These aspects
address a technical problem of congestion, and with it packet loss,
in a network by using "pacing" to reduce that congestion.
[1970] An advantage of this aspect is that the separate control of
pacing can prevent packets in the congestion window from being
transmitted too rapidly compared to the rate at which they are
getting through to the other side. Without separate pacing control,
at least some conventional TCP approaches would permit bursts of
overly rapid transmission of packets, which might result in packet
loss at an intermediate node on the communication path. These
packet losses may be effectively interpreted by the protocol as
resulting from congestion, resulting in the protocol reducing the
window size. However, the window size may be appropriate, for
example, for the available bandwidth and delay of the path, and
therefore reducing the window size may not be necessary. On the
other hand, reducing the peak transmission rate can have the effect
of avoiding packet loss, for example, by avoiding overflow of
intermediate buffers on the path.
[1971] Another advantage of at least some implementations is
prevention of large bursts of packet losses under convex window
increase functions for high-bandwidth scenarios, by providing an
additional finer level of control over the transmission
process.
[1972] At least some implementations of the approach can leverage
the advantages of existing high-bandwidth variants of TCP such as
H-TCP and CUBIC, while preventing large bursts of packet losses
under their convex window increase functions and providing a more
precise level of control. For example, pacing control may be
implemented to pace the rate of providing packets from the existing
TCP procedure to the channel, with the existing TCP procedure
typically further or separately limiting the presentation of
packets to the communication channel based, for instance, on its
window-based congestion control procedure.
[1973] In practice, a particular example in which separating pacing
from window control has been observed to significantly outperform
conventional TCP on 4G LTE.
[1974] Referring to FIG. 214, in one example, a source application
1010 passes data to a destination application 1090 over a
communication channel 1050. Communication from the source
application 1010 passes to a transport layer 1020, which maintains
a communication session with a corresponding transport layer 1080
linked to the destination application 1090. In general, the
transport layers may be implemented as software that executes on
the same computer as their corresponding applications, however, it
should be recognized that, for instance through the use of proxy
approaches, the applications and the transport layer elements that
are shown may be split over separate coupled computers. In
embodiments, when a proxy is running on a separate machine or
device from the application, the application may use the transport
layer on its machine to communicate with the proxy layer.
[1975] In FIG. 214, the transport layer 1020 at the source
application includes a window control and retransmission element
1030. In some implementations, this element implements a
conventional Transport Control Protocol (TCP) approach, for
instance, implementing H-TCP or CUBIC approaches. In other
implementations, this element implements the novel congestion
control algorithms described herein. The transport layer 1080 at
the destination may implement a corresponding element 1060, which
may provide acknowledgements of packets to the window control and
retransmission element 1030 at the source. In general, element 1030
may implement a window-based congestion control approach based on
acknowledgements that are received at the destination, however it
should be understood that no particular approach to window control
is essential, and in some implementations, element 1030 can be
substituted with another element that implements congestion control
using approaches other than window control.
[1976] Functionally, one may consider two elements of the protocol
as being loss recovery and rate/congestion control. Loss recovery
can be implemented either using conventional retransmissions or
using coding or as a combination of retransmission and coding.
Rate/congestion control may aim to avoid overrunning the receiver
and/or the available channel capacity, and may be implemented using
window control with or without pacing, or direct rate control.
[1977] The channel 1050 coupling the transport layers in general
may include lower layer protocol software at the source and
destination, and a series of communication links coupling computers
and other network nodes on a path from the source to the
destination.
[1978] As compared to conventional approaches, as shown in FIG.
192, a rate control element 1040 may be on the path between the
window control and retransmission element 1030 and the channel
1050. This rate control element may monitor acknowledgements that
are received from the destination, and may pass them on to the
window control and retransmission element 1030, generally without
delay. The rate control element 1040 receives packets for
transmission on the channel 1050 from the window control and
retransmission element 1030, and either passes them directly to the
channel 1050, or buffers them to limit a rate of transmission onto
the channel. For example, the rate control element 1040 may require
a minimum interval between successive packets, or may control an
average rate over multiple packets.
[1979] In embodiments, the acks that are transmitted on a return
channel, from the destination to the source, may also be paced, and
may also utilize coding to recover from erasures and bursty losses.
In embodiments, packet coding and transmission control of the acks
may be especially useful if there is congestion on the return
channel.
[1980] In one implementation, the rate control element 1040 may
maintain an average (i.e., smoothed) inter-packet delivery
interval, estimated based on the acknowledgement intervals
(accounting for the number of packets acknowledged in each ack). In
some implementations this averaging may be computed as a decaying
average of past sample inter-arrival times. This can be refined by
incorporating logic for discarding large sample values based on the
determination of whether they are likely to have resulted from a
gap in the sending times or losses in the packet stream, and by
setting configurable upper and lower limits on the estimated
interval commensurate with particular characteristics of different
known networks. The rate control element 1040 may then use this
smoothed inter-acknowledgement time to set a minimum
inter-transmission time, for example, as a fraction of the
inter-acknowledgement time. This fraction can be increased with
packet loss and with rate of increase of RTT (which may be
indicators that the current sending rate may be too high), and
decreased with rate of decrease of RTT under low loss, e.g. using a
control algorithm such as proportional control whose parameters can
be adjusted to trade off between stability and responsiveness to
change. Upper and lower limits on this fraction can be made
configurable parameters, say 0.2 and 0.95. Transmission packets are
then limited to be presented to the channel 1050 with
inter-transmission times of at least this set minimum. In other
implementations inter-transmission intervals are controlled to
maintain a smoothed average interval or rate based on a smoothed
inter-acknowledgement interval or rate.
[1981] In addition to the short timescale adjustments of the pacing
interval with estimated delivery interval, packet loss rate and RTT
described above, there can also be a longer timescale control loop
that modulates the overall aggressiveness of the pacing algorithm
based on a smoothed loss rate calculated over a longer timescale,
with, a higher loss rate indicating that pacing may be too
aggressive. The longer timescale adjustment can be applied across
short duration connections by having the client maintain state
across successive connections and include initializing information
in subsequent connection requests. This longer timescale control
may be useful for improving adaptation to diverse network scenarios
that change dynamically on different timescales.
[1982] Referring to FIG. 215, in some implementations, the
communication channel 1050 spans multiple nodes 1161, 1162 in one
or an interconnection of communication networks 1151, 1152. In FIG.
193, the source application 1010 is illustrated as co-resident with
the transport layer 1020 on a source computer 1111, and similarly,
the transport layer 1080 is illustrated as co-resident on a
destination computer 1190 with the destination application
1090.
[1983] It should be recognized that although the description above
focuses on a single direction of communication, in general, a
bidirectional implementation would include a corresponding path
from the destination application to the source application. In some
implementations, both directions include corresponding rate control
elements 1040, while in other applications, only one direction
(e.g., from the source to the destination application) may
implement the rate control. For example, introduction of the rate
control element 1040 at a server, or another device or network node
on the path between the source application and the transport layer
1080 at the destination, may not require modification of the
software at the destination.
Pacing by Receiver
[1984] As described above, the sender can use acks to estimate the
rate/interval with which packets are reaching the receiver, the
loss rate and the rate of change of RTT, and adjust the pacing
interval accordingly. However, this estimated information may be
noisy if acks are lost or delayed. On the other hand, such
information can be estimated more accurately at the receiver with
OWTT in place of RTT. By basing the pacing interval on the rate of
change of OWTT rather than its actual value, the need for
synchronized clocks on sender and receiver may be obviated. The
pacing interval can be fed back to the sender by including it as an
additional field in the acks. The choice as to whether the pacing
calculations are done at the sender or the receiver, or done every
n packets rather than upon every packet reception, may also be
affected by considerations of sender/receiver CPU/load.
Error Control
[1985] Classical TCP performs poorly on networks with packet
losses. Congestion control can be combined with coding such that
coded packets are sent both for forward error correction (FEC) to
provide protection against an anticipated level of packet loss, as
well as for recovering from actual losses indicated by feedback
from the receiver.
[1986] While the simple combination of packet coding and congestion
control has been suggested previously, the prior art does not
adequately account for differences between congestion-related
losses, bursty and/or random packet losses. Since
congestion-related loss may occur as relatively infrequent bursts,
it may be inefficient to protect against this type of loss using
FEC.
[1987] In at least some embodiments, the rates at which loss events
occur are estimated. A loss event may be defined as either an
isolated packet loss or a burst of consecutive packet losses. In
some examples, the source PC-TCP may send FEC packets at the
estimated rate of loss events, rather than the estimated rate of
packet loss. This embodiment is an efficient way to reduce
non-useful FEC packets, since it may not be disproportionately
affected by congestion-related loss.
[1988] In an exemplary embodiment, the code rate and/or packet
transmission rate of FEC can be made tunable in order to trade-off
between the useful throughput seen at the application layer (also
referred to as goodput) and recovery delay. For instance, the ratio
of the FEC rate to the estimated rate of loss events can be made a
tunable parameter that is set with a priori knowledge of the
underlying communications paths or dynamically adjusted by making
certain measurements of the underlying communications paths.
[1989] In another exemplary embodiment, the rate at which loss
bursts of up to a certain length occur may be estimated, and
appropriate burst error correcting codes for FEC, or codes that
correct combinations of burst and isolated errors, may be used.
[1990] In another exemplary embodiment, the FEC for different
blocks can be interleaved to be more effective against bursty
loss.
[1991] In other exemplary embodiments, data packets can be sent
preferentially over FEC packets. For instance, FEC packets can be
sent at a configured rate or estimated loss rate when there are no
data packets to be sent, and either not sent or sent at a reduced
rate when there are data packets to be sent. In one implementation,
FEC packets are placed in a separate queue which is cleared when
there are data packets to be sent.
[1992] In other exemplary embodiments, the code rate/amount of FEC
in each block and/or the FEC packet transmission rate can be made a
tunable function of the block number and/or the number of packets
in flight relative to the number of unacknowledged degrees of
freedom of the block, in addition to the estimated loss rate. FEC
packets for later blocks can be sent preferentially over FEC for
earlier blocks, so as to minimize recovery delay at the end of a
connection, e.g., the number of FEC packets sent from each block
can be a tunable function of the number of blocks from the latest
block that has not been fully acknowledged. The sending interval
between FEC packets can be an increasing function of the number of
packets in flight relative to the number of unacknowledged degrees
of freedom of the corresponding block, so as to trade-off between
sending delay and probability of losing FEC packets in scenarios
where packet loss probability increases with transmission rate.
[1993] In other exemplary embodiments, a variable randomly chosen
fraction of the coding coefficients of a coded packet can be set to
1 or 0 in order to reduce encoding complexity without substantially
affecting erasure correction performance. In a systematic code,
introducing 0 coefficients only after one or more densely coded
packets (i.e. no or few 0 coefficients) may be important for
erasure correction performance. For instance, an initial FEC packet
in a block could have each coefficient set to 1 with probability
0.5 and to a uniformly random value from the coding field with
probability 0.5. Subsequent FEC packets in the block could have
each coefficient set to 0 with probability 0.5 and to uniformly
random value with probability 0.5.
Packet Reordering
[1994] As introduced above, packets may be received out of order on
some networks, for example, due to packets traversing multiple
paths, parallel processing in some networking equipment,
reconfiguration of a path (e.g., handoff in cellular networks).
Generally, conventional TCP reacts to out of order packets by
backing off the size of the congestion window. Such a backoff may
unnecessarily hurt performance if there is no congestion
necessitating a backoff.
[1995] In some embodiments, in an approach to handling packet
reordering that does not result from congestions, a receiver
observing a gap in the sequence numbers of its received packets may
delay sending an acknowledgment for a limited time. When a packet
is missing, the receiver does not immediately know if the packet
has been lost (erased), or merely reordered. The receiver delays
sending an acknowledgement that indicates the gap to see if the gap
is filled by subsequent packet arrivals. In some examples, upon
observing a gap, the receiver starts a first timer for a
configurable "reordering detection" time interval, e.g. 20 ms. If a
packet from the gap is subsequently received within this time
interval, the receiver starts a second timer for a configurable
"gap filling" time interval, e.g. 30 ms. If the first timer or the
second timer expire prior to the gap being filled, an
acknowledgement that indicates the gap is sent to the source.
[1996] Upon receiving the acknowledgment that indicates the gap in
received packets the source, in at least some embodiments, the
sender determines whether a repair packet should be sent to
compensate for the gap in the received packets, for example, if a
sufficient number of FEC packets have not already been sent.
[1997] In another aspect, a sender may store relevant congestion
control state information (including the congestion window) prior
to backoff, and a record of recent packet losses. If the sender
receives an ack reporting a gap/loss and then subsequently one or
more other acks reporting that the gap has been filled by out of
order packet receptions, any backoff caused by the earlier ack can
be reverted by restoring the stored state from before backoff.
[1998] In another aspect, a sender observing a gap in the sequence
numbers of its received acks may delay congestion window backoff
for a limited time. When an ack is missing, the sender does not
immediately know if a packet has been lost or if the ack is merely
reordered. The sender delays backing off its congestion window to
see if the gap is filled by subsequent ack arrivals. In some
examples, upon observing a gap, the sender starts a first timer for
a configurable "reordering detection" time interval, e.g. 20 ms. If
an ack from the gap is subsequently received within this time
interval, the sender starts a second timer for a configurable "gap
filling" time interval, e.g. 30 ms. If the first timer or the
second timer expires prior to the gap being filled, congestion
window backoff occurs.
[1999] In some examples, instead of using time intervals, packet
sequence numbers are used. For example, sending of an ack can be
delayed until a packet which is a specified number of sequence
numbers ahead of the reference lost packet is received. Similarly,
backing off can be delayed until an acknowledgment of a packet
which is a specified number of sequence numbers ahead of the
reference lost packet is received. In some examples, these
approaches have the advantage of being able to take into account
subsequently received/acknowledged reordered packets by shifting
the sequence number of the reference lost packet as holes in the
packet sequence get filled.
[2000] These methods for correcting packet reordering may be
especially useful for multipath versions of the protocol, where
there may be a large amount of reordering.
Acknowledgements
Delayed Acknowledgements
[2001] In at least some implementations, conventional TCP sends one
acknowledgment for every two data packets received. Such delayed
acking reduces ack traffic compared to sending an acknowledgment
for every data packet. This reduction in ack traffic is
particularly beneficial when there is contention on the return
channel, such as in Wi-Fi networks, where both data and ack
transmissions contend for the same channel.
[2002] It is possible to reduce ack traffic further by increasing
the ack interval to a value n>2, i.e. sending one acknowledgment
for every n data packets. However, reducing the frequency with
which acks are received by the sender can cause delays in
transmission (when the congestion window is full) or backoff (if
feedback on losses is delayed), which can hurt performance.
[2003] In one aspect, the sender can determine whether, or to what
extent, delayed acking should be allowed based in part on its
remaining congestion window (i.e. its congestion window minus the
number of unacknowledged packets in flight), and/or its remaining
data to be sent. For example, delayed acking can be disallowed if
there is any packet loss, or if the remaining congestion window is
below some (possibly tunable) threshold. Alternatively, the ack
interval can be reduced with the remaining congestion window. As
another example, delayed acking can be allowed if the amount of
remaining data to be sent is smaller than the remaining congestion
window, but disallowed for the last remaining data packet so that
there is no delay in acknowledging the last data packet. This
information can be sent in the data packets as a flag indicating
whether delayed acking is allowed, or for example, as an integer
indicating the allowed ack interval.
[2004] Using relevant state information at the sender to influence
delayed acking may allow an increase in the ack interval beyond the
conventional value of 2, while mitigating the drawbacks described
above that a larger ack interval across the board might have.
[2005] To additionally limit the ack delay, each time an ack is
sent, a delayed ack timer can be set to expire with a configured
delay, say 25 ms. Upon expiration of the timer, any data packets
received since the last ack may be acknowledged, even if fewer
packets than the ack interval n have arrived. If no packets have
been received since the last ack, an ack may be sent upon receipt
of the next data packet.
Parameter Control
Initialization
[2006] In some embodiments, to establish a session parameters for
the PC-TCP modules are set to a predefine set of default
parameters. In other embodiments, approaches that attempt to select
better initial parameters are used. Approaches include use of
parameter values from other concurrent or prior PC-TCP sessions,
parameters determined from characteristics of the communication
channel, for example, selected from stored parameters associated
with different types of channels, or parameters determined by the
source or destination application according to the nature of the
data to be transported (e.g., batch versus stream).
Tunable Coding
[2007] Referring to FIG. 216, in an embodiment in which parameters
are "tuned" (e.g., through feedback from a receiver or on other
considerations) a server application 2411 is in communication with
a client application 2491 via a communication channel 2452. In one
example, the server application 2411 may provide a data stream
encoding multimedia content (e.g., a video) that is accepted by the
client application 2491, for example, for presentation to a user of
the device on which the client application is executing. The
channel 2452 may represent what is typically a series of network
links, for example including links of one or more types,
including:
[2008] a link traversing private links on a server local area
network,
[2009] a link traversing the public Internet,
[2010] a link traversing a fixed (i.e., wireline) portion of a
cellular telephone network,
[2011] and a link traversing a wireless radio channel to the user's
device (e.g., a cellular telephone channel or satellite link or
wireless LAN).
[2012] The channel 2452 may be treated as carrying a series of data
units, which may but do not necessarily correspond directly to
Internet Protocol (IP) packets. For example, in some
implementations multiple data units are concatenated into an IP
packet, while in other implementations, each data unit uses a
separate IP packet or only part of an IP packet. It should be
understood that in yet other implementations, the Internet Protocol
is not used--the techniques described below do not depend on the
method of passing the data units over the channel 2452.
[2013] A transmitter 2421 couples the server application 2411 to
the channel 2452, and a receiver 2481 couples the channel 2452 to
the client application 2491. Generally, the transmitter 2421
accepts input data units from the server application 2481. In
general, these data units are passed over the channel 2452, as well
as retained for a period of time in a buffer 2423. From time to
time, an error control (EC) component 2425 may compute a redundancy
data unit from a subset of the retained input data units in the
buffer 2423, and may pass that redundancy data unit over the
channel 2452. The receiver 2481 accepts data units from the channel
2452. In general, the channel 2452 may erase and reorder the data
units. Erasures may correspond to "dropped" data units that are
never received at the receiver, as well as corrupted data units
that are received, but are known to have irrecoverable errors, and
therefore are treated for the most part as dropped units. The
receiver may retain a history of received input data units and
redundancy data units in a buffer 2483. An error control component
2485 at the receiver 2481 may use the received redundancy data
units to reconstruct erased input data units that may be missing in
the sequence received over the channel. The receiver 2481 may pass
the received and reconstructed input data units to the client
application. In general, the receiver may pass these input data
units to the client application in the order they were received at
the transmitter.
[2014] In general, if the channel has no erasures or reordering,
the receiver can provide the input data units to the client
application with delay and delay variation that may result from
traversal characteristics of the channel. When data units are
erased in the channel 2452, the receiver 2481 may make use of the
redundancy units in its buffer 2483 to reconstruct the erased
units. In order to do so, the receiver may have to wait for the
arrival of the redundancy units that may be useful for the
reconstruction. The way the transmitter computes and introduces the
redundancy data units generally affects the delay that may be
introduced to perform the reconstruction.
[2015] The way the transmitter computes and introduces the
redundancy data units as part of its forward error correction
function can also affect the complexity of the reconstruction
process at the receiver, and the utilization of the channel.
Furthermore, regardless of the nature of the way the transmitter
introduces the redundancy data units onto the channel,
statistically there may be erased data units for which there is
insufficient information in the redundancy data units to
reconstruct the erased unit. In such cases, the error control
component 2485 may request a retransmission of information from the
error control component 2425 of the transmitter 2421. In general,
this retransmitted information may take the form of further
redundancy information that depends on the erased unit. This
retransmission process introduces a delay before the erased unit is
available to the receiver. Therefore, the way the transmitter
introduces the redundancy information also affects the statistics
such as how often retransmission of information needs to be
requested, and with it the delay in reconstructing the erased unit
that cannot be reconstructed using the normally introduced
redundancy information.
[2016] In some embodiments, the error control component 2485 may
provide information to the error control component 2425 to affect
the way the transmitter introduces the redundancy information. In
general, this information may be based on one or more of the rate
of (or more generally the pattern of) erasures on units on the
channel, rate of (or more generally timing pattern of) and the
state of the available units in the buffer 2483 and/or the state of
unused data in the client application 2491. For example, the client
application may provide a "play-out time" (e.g., in milliseconds)
of the data units that the receiver has already provided to the
client application such that if the receiver were to not send any
more units, the client application would be "starved" for input
units at that time. Note that in other embodiments, rather than or
in addition to receiving information from the receiver, the error
control component 2425 at the transmitter may get feedback from
other places, for example, from instrumented nodes in the network
that pass back congestion information.
[2017] Referring to FIG. 217, a set of exemplary ways that the
transmitter introduces the redundancy data units into the stream of
units passed over the channel makes use of alternating runs of
input data units and redundancy data units. In FIG. 217, the data
units that are "in flight" on the channel 2452 are illustrated
passing from left to right in the figure. The transmitter
introduces the units onto the channel as sequences of p input units
alternating with sequences of q redundancy units. Assuming that the
data units are the same sizes, this corresponds to a rate R=p/(p+q)
code. In an example with p=4 and q=2 and the code has rate
R=2/3.
[2018] In a number of embodiments the redundancy units are computed
as random linear combinations of past input units. Although the
description below focuses on such approaches, it should be
understood that the overall approach is applicable to other
computations of redundancy information, for example, using low
density parity check (LDPC) codes and other error correction codes.
In the approach shown in FIG. 217, each run of q redundancy units
is computed as a function of the previous D input units, where in
general but not necessarily D>p. In some cases, the most recent
d data units transmitted are not used, and therefore the redundancy
data units are computed from a window of D-d input data units. In
FIG. 217, d=2, D=10, and D-d=8. Note that because D-d>p, the
windows of input data units used for computation of the successive
runs of redundancy units overlap, such that any particular input
data unit will in general contribute to redundancy data units in
more than one of the runs of q units on the channel.
[2019] In FIG. 217, as well as in FIGS. 218-219 discussed below,
buffered input data units (i.e., in buffer 2423 shown in FIG. 216)
are shown on the left with time running from the bottom (past) to
the top (future), with each set of D-d units used to compute a run
of q redundant units illustrated with arrows. The sequence of
transmitted units, consisting of runs of input data units
alternating with runs of redundant units, is shown with time
running from right to left (i.e., later packets on the left). Data
units that have been received and buffered at the receiver are
shown on the right (oldest on the bottom), redundant units computed
from runs of D-d input units indicated next to arrows representing
the ranges of input data units used to compute those data units.
Data units and ranges of input data units that have not yet been
received are illustrated using dashed lines.
[2020] FIGS. 218 and 219 show different selections of parameters.
In FIGS. 218, p=2 and q=1 and the code has a rate R=2/3, which is
the same rate at the selection of parameters in FIG. 217. Also as
in the FIG. 217 selection, d=2, D=10, and D-d=8. Therefore, a
difference between FIG. 217 and FIG. 218 is not necessarily a
degree of forward error protection (although the effect of burst
erasures may be somewhat different in the two cases). More
importantly, the arrangement in FIG. 218 generally provides a lower
delay from the time of an erased data unit to the arrival of
redundancy information to reconstruct that unit, as compared to the
arrangement in FIG. 217. On the other hand, the complexity of
processing at the receiver may be greater in the arrangement of
FIG. 218 as compared to the arrangement of FIG. 216, in part
because redundancy units information uses multiple different
subsets of the input data units, which may require more computation
when reconstructing an erased data unit. Turning to FIG. 219, at
another extreme, a selection of parameters uses longer blocks with
a selection D=8 and q=4. Again, this code has a rate R=2/3. In
general, this selection of parameters will incur greater delay in
reconstruction of an erased data unit as compared to the selections
of parameters shown in FIGS. 217 and 218. On the other hand,
reconstruction of up to four erasures per block of D=8 input data
units is relatively less complex than would be required by the
selections shown in FIGS. 217 and 218.
[2021] For a particular rate of code (e.g., rate R=2/3), in an
example, feedback received may result in changes of the parameters,
for example, between (p,q)=(2,1) or (4,2) or (8,4) depending on of
the amount of data buffered at the receiver, and therefore
depending on the tolerance of the receiver to reconstruction
delay.
[2022] Note that it is not required that q=p(1-R)/R is an integer,
as it is in the examples shown in FIGS. 25-27. In some embodiments,
the length of the run of redundant units varies between q=.left
brkt-top.p(1-R)/R.right brkt-bot. and q=.left
brkt-bot.p(1-R)/R.right brkt-bot. so that the average is
ave(q)=p(1-R)/R.
[2023] In a variant of the approach described above, different
input data units have different "priorities" or "importances" such
that they are protected to different degrees than other input data
units. For example, in video coding, data units representing an
independently coded video frame may be more important than data
units representing a differentially encoded video frame. For
example, if the priority levels are indexed i=1, 2, . . . , then a
proportion .rho..sub.i.ltoreq.1, where .SIGMA..sub.i.rho..sub.i=1,
of the redundancy data units may be computed using data units with
priority .ltoreq.i. For example, for a rate R code, with blocks of
input data units of length p, on average .rho..sub.ip(1-R)/R
redundancy data units per block are computed from input data units
with priority .ltoreq.i.
[2024] The value of D should generally be no more than the target
playout delay of the streaming application minus an appropriate
margin for communication delay variability. The playout delay is
the delay between the time a message packet is transmitted and the
time it should be available at the receiver to produce the
streaming application output. It can be expressed in units of time,
or in terms of the number of packets transmitted in that interval.
D can be initially set based on the typical or desired playout
delay of the streaming application, and adapted with additional
information from the receiver/application. Furthermore, choosing a
smaller value reduces the memory and complexity at the expense of
erasure correction capability.
[2025] The parameter d specifies the minimum separation between a
message packet and a parity involving that message packet. Since a
parity involving a message packet that has not yet been received is
not useful for recovering earlier message packets involved in that
parity, setting a minimum parity delay can improve decoding delay
when packet reordering is expected/observed to occur, depending
partly also on the parity interval.
[2026] Referring to FIG. 220, in an example implementation making
use of the approaches described above, the server application 2411
is hosted with the transmitter 2421 at a server node 810, and the
client application 2491 is hosted at one or a number of client
nodes 891 and 892. Although a wide variety of types of data may be
transported using the approaches described above, one example is
streaming of encoded multimedia (e.g., video and audio) data. The
communication channel 2452 (see FIG. 216) is made up in this
illustration as a path through one or more networks 851-852 via
nodes 861-862 in those respective networks. In some
implementations, the receiver is hosted at a client node 891 being
hosted on the same device as the client application 490.
Cross-Session Parameter Control
[2027] In some embodiments, the control of transport layer sessions
uses information across connections, for example, across concurrent
sessions or across sessions occurring at different times.
[2028] Standard TCP implements end-to-end congestion control based
on acknowledgments. A new TCP connection that has started up but
not yet received any acknowledgments uses initial configurable
values for the congestion window and retransmission timeout. These
values may be tuned for different types of network settings.
[2029] Some applications, for instance web browser applications,
may use multiple connections between a client application (e.g.,
the browser) and a server application (e.g., a particular web
server application at a particular server computer).
Conventionally, when accessing the information to render a single
web "page", the client application may make many separate TCP
sessions between the client and server computers, and using
conventional TCP control, each session is controlled substantially
independently. This independent control includes separate
congestion control.
[2030] One approach to addressing technical problems that are
introduced by having such multiple sessions is the SPDY Protocol
(see, e.g., SPDY Protocol--Draft 3.1, accessible at
http://www.chromium.org/spdy/spdy-protocol/spdy-protocol-draft3-1).
The SPDY protocol is an application layer protocol that manipulates
HTTP traffic, with particular goals of reducing web page load
latency and improving web security. Generally, SPDY effectively
provides a tunnel for the HTTP and HTTPS protocols. When sent over
SPDY, HTTP requests are processed, tokenized, simplified and
compressed. The resulting traffic is then sent over a single TCP
session, thereby avoiding problems and inefficiencies involved in
use of multiple concurrent TCP sessions between a particular client
and server computer.
[2031] In a general aspect, a communication system maintains
information related to communication between computers or network
nodes. For example, the maintained information can include
bandwidth to and/or from the other computer, current or past
congestion window sizes, pacing intervals, packet loss rates,
round-trip time, timing variability, etc. The information can
include information for currently active sessions and/or
information about past sessions. One use of the maintained
information may be to initialize protocol parameters for a new
session between computers for which information has been
maintained. For example, the congestion window size or a pacing
rate for a new TCP or UDP session may be initialized based on the
congestion window size, pacing interval, round-trip time and loss
rate of other concurrent or past sessions.
[2032] Referring to FIG. 221, communication system 1200 maintains
information regarding communication sessions between endpoints. For
example, these communication sessions pass via a network 1250, and
may pass between a server 1210, or a proxy 1212 serving one or more
servers 1214, and a client 1290. In various embodiments, this
information may be saved in various locations. In some
implementations, a client 1290 maintains information about current
or past connections. This information may be specific to a
particular server 1210 or proxy 1212. This information may also
include aggregated information. For example, in the case of a
smartphone on a cellular telephone network, some of the information
may be generic to connections from multiple servers and may
represent characteristics imposed by the cellular network rather
than a particular path to a server 1210. In some implementations, a
server 1210 or proxy 1212 may maintain the information based on its
past communication with particular clients 1290. In some examples,
the clients and servers may exchange the information such that is
it distributed throughout the system 1200. In some implementations,
the information may be maintained in databases that are not
themselves endpoints for the communication sessions. For instance,
it may be beneficial for a client without relevant stored
information to retrieve information from an external database.
[2033] In one use scenario, when a client 1290 seeks to establish a
communication session (e.g., a transport layer protocol session),
it consults its communication information 1295 to see if it has
current information that is relevant to the session it seeks to
establish. For example, the client may have other concurrent
sessions with a server with which it wants to communicate, or with
which it may have recently had such sessions. As another example,
the client 1290 may use information about other concurrent or past
sessions with other servers. When the client 1290 sends a request
to a server 1210 or a proxy 1212 to establish a session, relevant
information for that session is also made available to one or both
of the endpoints establishing the session. There are various ways
in which the information may be made available to the server. For
example the information may be included with the request itself. As
another example, the server may request the information if it does
not already hold the information in its communication information
1215. As another example, the server may request the information
from a remote or third party database, which has been populated
with information from the client or from servers that have
communicated with the client. In any case, the communication
session between the client and the server is established using
parameters that are determined at least in part by the
communication information available at the client and/or
server.
[2034] In some examples, the communication session may be
established using initial values of packet pacing interval,
congestion window, retransmission timeout and forward error
correction. Initial values suitable for different types of networks
(e.g. Wi-Fi, 4G), network operators and signal strength can be
prespecified, and/or initial values for successive connections can
be derived from measured statistics of earlier connections between
the same endpoints in the same direction. For example:
[2035] The initial congestion window can be increased from its
default value if the packet throughput of the previous connection
is sufficiently larger than the ratio of the default initial
congestion window to the minimum round-trip time of the previous
connection. The congestion window can subsequently be adjusted
downwards if the initial received acks from the new connection
indicate that the available rate has decreased compared to the
previous connection.
[2036] The initial pacing interval can be set e.g. as
MAX(k1*congestion window/previous round-trip time, k2/previous
packet throughput), where k1 and k2 are configurable parameters,
or, with receiver pacing, as k* previous pacing interval, where k
increases with the loss rate of the previous connection.
[2037] Forward error correction parameters such as code rate can be
set as k*previous loss rate, where k is a configurable parameter.
The initial retransmission timeout can be increased from its
default value if the minimum round-trip time of the previous
connection is larger.
Multi-Path
[2038] FIG. 222 shows the use of multiple paths between the server
and client to deliver the packet information. These multiple paths
may be over similar or different network technologies with similar
or different average bandwidth, round trip delay, packet jitter
rate, packet loss rate and cost. Examples of multiple paths include
wired/fiber networks, geostationary, medium and low earth orbit
satellites, WiFi, and cellular networks. In this example, the
transmission control layer can utilize a single session to
distribute the N packets in the block being transmitted over the
multiple paths according to a variety of metrics (average bandwidth
of each path, round trip delay of each path, packet jitter rate,
packet loss rate of each path, and cost). The N packets to be
transmitted in each block can be spread across each path in a
manner that optimizes the overall end-to-end throughput and costs
between server and client. The number of packets sent on each path
can be dynamically controlled such that the average relative
proportions of packets sent on each path are in accordance with the
average relative available bandwidths of the paths, e.g. using back
pressure-type control whereby packets are scheduled so as to
approximately equalize queue lengths associated with the different
paths.
[2039] For each path, the algorithms described above that embody
transmission and congestion control, forward error correction,
sender based pacing, receiver based pacing, stream based parameter
tuning, detection and correction for missing and out of order
packets, use of information across multiple TCP connections, fast
connection start and stop, TCP/UDP fallback, cascaded coding,
recoding by intermediate nodes, and coding of the ACKs can be
employed to improve the overall end-to-end throughput over the
multiple paths between the source node and destination node. When
losses are detected and FEC is used, the extra coded packets can be
sent over any or all of the paths. For instance, coded packets sent
to repair losses can be sent preferentially over lower latency
paths to reduce recovery delay. The destination node will decode
any N of packets that are received over all of the paths and
assemble them into a block of N original packets by recreating any
missing packets from the ones received. If less than N different
coded packets are received across all paths, then the destination
node will request the number of missing packets x where x=N-number
of packets received be retransmitted. Any set of x different coded
packet can be retransmitted over any path and then used to
reconstruct the missing packets in the block of N.
[2040] When there are networks with large differences in round trip
time (RTT) latencies, the packets received over the lower RTT
latencies will need to be buffered at the receiver in order to be
combined with the higher RTT latency packets. The choice of packets
sent on each path can be controlled so as to reduce the extent of
reordering and associated buffering on the receiver side, e.g.
among the packets available to be sent, earlier packets can be sent
preferentially on higher latency paths and later packets can be
sent preferentially on lower latency paths.
[2041] Individual congestion control loops may be employed on each
path to adapt to the available bandwidth and congestion on the
path. An additional overall congestion control loop may be employed
to control the total sending window or rate across all the paths of
a multi-path connection, for fairness with single-path
connections.
[2042] Referring to FIG. 223, a communication system utilizes a
first, satellite data path 3102 having a relatively high round trip
time latency and a second, DSL data path 3104 having a relatively
low round trip time latency. When a user application 3106 sends a
request to stream video content, a content server 3108 (e.g., video
streaming service) provides some or all of the requested video
content to a remote proxy 3110 which generates encoded video
content 3112 for transmission to the user application 3106. Based
on the RTT latencies of the first data path 3102 and the second
data path 3104, the remote proxy 3110 splits the encoded video
content 3112 into an initial portion 3114 (e.g., the first 5
seconds of video content) and a subsequent portion 3116 (e.g., the
remaining video content). The remote proxy 3110 then causes
transmission of the initial portion 3114 over the second, low
latency data path 3104 and transmission of the subsequent portion
3116 over the first, high latency data path 3102.
[2043] Referring to FIG. 224, due to the lower latency of the
second data path 3104, the initial portion 3114 of the video
content arrives at the local proxy 3118 quickly, where it is
decoded and sent to the user application 3106 for presentation to a
viewer. The subsequent portion 3116 of the video content is still
traversing the first, high latency data path 3102 at the time that
presentation of the initial portion 3114 of the video content to
the viewer commences.
[2044] Referring to FIG. 225, during presentation of the decoded
initial portion 3114 of video content to the viewer, the subsequent
portion 3116 of the video content arrives at the local proxy 3118
where it is decoded and sent to the user application 3106 before
presentation of the initial portion 3114 of the video content to
the viewer is complete. In some examples, sending the initial
portion 3114 of the video content over the low latency data path
3104 and sending a subsequent portion 3116 of the video content
over the high latency data path 3102 avoids lengthy wait times
between when a user requests a video and when the user sees the
video (as would be the case if using satellite only communication)
while minimizing data usage over the low latency data path (which
may be more costly to use).
[2045] In some examples, other types of messages may be
preferentially sent over the low latency data path. For example,
acknowledgement messages, retransmission messages, and/or other
time critical messages may be transmitted over the low latency data
path while other data messages are transmitted over the higher
latency data path.
[2046] In some examples, additional data paths with different
characteristics (e.g., latencies) can also be included in the
communication system, with messages being balanced over any of a
number of data paths based on characteristics of the messages
(e.g., message type) and characteristics of the data paths.
[2047] In some examples, other types of messages may be
preferentially sent over the low latency data path. For example,
acknowledgement messages, retransmission messages, and/or other
time critical messages may be transmitted over the low latency data
path while other data messages are transmitted over the higher
latency data path.
[2048] In some examples, additional data paths with different
characteristics (e.g., latencies) can also be included in the
communication system, with messages being balanced over any of a
number of data paths based on characteristics of the messages
(e.g., message type) and characteristics of the data paths.
Alternatives and Implementations
[2049] In the document above, certain features of the packet coding
and transmission control protocols are described individually, or
in isolation, but it should be understood that there are certain
advantages that may be gained by combining multiple features
together. Preferred embodiments for the packet coding and
transmission control protocols described may depend on whether the
transmission links and network nodes traversed between
communication session end-points belong to certain fiber or
cellular carriers (e.g. AT&T, T-Mobile, Sprint, Verizon, Level
3) and/or end-user Internet Service Providers (ISPs) (e.g.
AT&T, Verizon, Comcast, Time Warner, Century Link, Charter,
Cox) or are over certain wired (e.g. DSL, cable,
fiber-to-the-curb/home (FTTx)) or wireless (e.g. WiFi, cellular,
satellite) links. In embodiments, probe transmissions may be used
to characterize the types of network nodes and transmission links
communication signals are traversing and the packet coding and
transmission control protocol may be adjusted to achieve certain
performance. In some embodiments, data transmissions may be
monitored to characterize the types of network nodes and
transmission links communication signals are traversing and the
packet coding and transmission control protocol may be adjusted to
achieve certain performance. In at least some embodiments,
quantities such as round-trip-time (RTT), one-way transmission
times (OWTT), congestion window, pacing rate, packet loss rate,
number of overhead packets, and the like may be monitored
continuously, intermittently, in response to a trigger signal or
event, and the like. In at least some embodiments, combinations of
probe transmissions and data transmissions may be used to
characterize network and communication session performance in real
time.
[2050] In at least some embodiments, network and communication
parameters may be stored in the end-devices of communication
sessions and/or they may be stored in network resources such as
servers, switches, nodes, computers, databases and the like. These
network and communication parameters may be used by the packet
coding and transmission control protocol to determine initial
parameter settings for the protocol to reduce the time it may take
to adjust protocol parameters to achieve adequate performance. In
embodiments, the network and communication parameters may be tagged
and/or associated with certain geographical locations, network
nodes, network paths, equipment types, carrier networks, service
providers, types of transmission paths and the like. In
embodiments, the end-devices may be configured to automatically
record and/or report protocol parameter settings and to associate
those settings with certain locations determined using GPS-type
location identification capabilities resident in those devices. In
embodiments, the end-devices may be configured to automatically
record and/or report protocol parameters settings and to associate
those settings with certain carrier networks, ISP equipment
traversed, types of wired and/or wireless links and the like.
[2051] In at least some embodiments, a packet coding and
transmission control protocol as described above may adjust more
than one parameter to achieve adequate or improved network
performance. Improved network performance may be characterized by
less delay in delivering data packets, less delay in completing
file transfers, higher quality audio and video signal delivery,
more efficient use of network resources, less power consumed by the
end-users, more end-users supported by existing hardware resources
and the like.
[2052] In at least some embodiments, certain modules or features of
the packet coding and transmission control protocol may be turned
on or off depending on the data's path through a network. In some
embodiments, the order in which certain features are implemented or
controlled may be adjusted depending on the data's path through a
network. In some embodiments, the probe transmissions and/or data
transmissions may be used in open-loop or closed-loop control
algorithms to adjust the adjustable parameters and/or the sequence
of feature implementation in the packet coding and transmission
control protocol.
[2053] It should be understood that examples which involve
monitoring to control the protocol can in general involve aspects
that are implemented at the source, the destination, or at a
combination of the source and the destination Therefore, it should
be evident that although embodiments are described above in which
features are described as being implemented at particular
endpoints, alternative embodiments involve implementation of those
features at different endpoints. Also, as described above,
monitoring to control the protocol can in general involve aspects
that are implemented intermediate nodes or points in the network.
Therefore, it should be evident that although embodiments are
described above in which features are described as being
implemented at particular endpoints, alternative embodiments
involve implementation of those features at different nodes,
including intermediate nodes, throughout the network.
[2054] In addition to the use of monitored parameters for control
of the protocols, the data may be used for other purposes. For
example, the data may support network analytics that are used, for
example, to control or provision the network as a whole.
[2055] The PC-TCP approaches may be adapted to enhance existing
protocols and procedures, and in particular protocols and
procedures used in content delivery, for example, as used in
coordinated content delivery networks. For instance, monitored
parameters may be used to direct a client to the server or servers
that can deliver an entire unit of content as soon as possible
rather than merely direct the client to a least loaded server or to
server accessible over a least congested path. A difference in such
an new approach is that getting an entire file as fast as possible
may require packets to be sent from multiple servers and/or servers
that are not geographically the closest, over multiple links, and
using new acknowledgement protocols that coordinate the incoming
data while requiring a minimum of retransmissions or FEC overhead.
Coordinating may include waiting for gaps in strings of packets
(out-of-order packets) to be filled in by later arriving packets
and/or by coded packets. In addition, the PC-TCP approaches may
improve the performance of wireless, cellular, and satellite links,
significantly improving the end-to-end network performance.
[2056] Some current systems use "adaptive bit rates" to try to
preserve video transmission through dynamic and/or poorly
performing links. In some instances, the PC-TCP approaches
described above replace adaptive bit rate schemes and may be able
to present a very high data rate to a user for a long period of
time. In other instances, the PC-TCP approaches are used in
conjunction with currently-available adaptive bit rate schemes to
support higher data rates on average than could be supported by
adaptive bit rate schemes alone. In some instances, the PC-TCP
approaches may include integrated bit rate adjustments as part of
its feature set and may use any and/or all of the previously
identified adjustable parameters and/or monitored parameters to
improve the performance of a combined PC-TCP and bit-rate adaptive
solution.
[2057] Certain embodiments described following relate to heating,
and more particularly to cooking and recipes, including by use of
intelligent devices, and in a context of the IoT.
[2058] With the emergence of the IoT, opportunities exist for
unlocking value surrounding a wide range of devices. To date, such
opportunities have been limited for many users, particularly in
rural areas of developing countries, by the absence of robust
energy and communications infrastructure. The same problems with
infrastructure also limit the ability of users to access more basic
features of certain devices; for example, rather than using modern
cooking systems, such as with gas burners, many rural users still
cook over fires, using wood or other biofuel. A need exists for
devices that meet basic needs, such as for modern cooking
capability, without reliance on infrastructure, and an opportunity
exists to expand the capabilities of basic cooking devices to
provide a much wider range of capabilities that will serve other
needs and provide other benefits to users of cooking devices.
[2059] Many industrial environments are similarly isolated from
conventional energy and communications infrastructure. For example,
offshore drilling platforms, industrial mining environments,
pipeline operations, large-scale agricultural environments, marine
exploration environments (e.g., deep ocean exploration), marine and
other large-scale transportation environments (such as ships,
boats, submarines, aircraft and spacecraft) are often entirely
isolated from the traditional power grid, or require very expensive
power transmission cables to receive power from traditional
sources. Other industrial environments are isolated for other
reasons, such as to maintain "clean room" isolation during
semi-conductor manufacturing, pharmaceutical preparation, or
handling of hazardous materials, where interfaces like outlets and
switches for delivering conventional power potentially provide
points of penetration or escape for contaminants or biologically
active materials. For these environments, a need exists for cooking
systems that provide improved independence from conventional power
sources. Also, in many of these environments fire is a significant
hazard, among other things because of the presence of fire hazards
and significant restrictions on egress for personnel. In those
cases, storage of fuel for cooking in an environment presents a
risk, because the fuel can exacerbate the extent of a fire,
potentially resulting in disastrous consequences. Accordingly, such
platforms and environments, such as oil drilling platforms, may use
diesel generators to power cooking and other systems, because
diesel is perceived as presenting lower risk than propane,
gasoline, or other fuel sources; however, diesel fuel also burns
and remains a significant hazard A need exists for safer mechanisms
for providing cooking capability in isolated industrial
environments.
[2060] Intelligent cooking systems are disclosed herein, including
an intelligent cooking system that is provided with processing,
communications, and other information technology components, for
remote monitoring and control and various value-added features and
services, embodiments of which use an electrolyzer, optionally a
solar-powered electrolyzer, to produce hydrogen as an on-demand
fuel stream for a heating element, such as a burner, of the cooking
system.
[2061] Embodiments of cooking systems disclosed herein include ones
for consumer and commercial use, such as for cooking meals in homes
and in restaurants, which may include various embodiments of
cooktops, stoves, toasters, ovens, grills and the like. Embodiments
of cooking systems also include industrial cooking systems, such as
for heating, drying, curing, and cooking not only food products and
ingredients, but also a wide variety of other products and
components that are manufactured in and/or used in the industrial
environments. These may include systems and components used in
assembly lines (such as for heating, drying, curing, or otherwise
treating parts or materials at one stage of production, such as to
treat coatings, polymers, or the like that are coated, dispersed,
painted, or otherwise disposed on components), in semi-conductor
manufacturing and preparation (such as for heating or curing layers
of a semi-conductor process, including in robotic assembly
processes), in tooling processes (such as for curing injection
molds and other molds, tools, dies, or the like), in extrusion
processes (such as for curing, heating or otherwise treating
results of extrusion), and many others. These may also include
systems and components used in various industrial environments for
servicing personnel, such as on ships, submarines, offshore
drilling platforms, and other marine platforms, on large equipment,
such as on mining or drilling equipment, cranes, or agricultural
equipment, in energy production environments, such as oil, gas,
hydro-power, wind power, solar power, and other environments.
Accordingly, while certain embodiments are disclosed for specific
environments, references to cooking systems should be understood to
encompass any of these consumer, commercial and industrial systems
for cooking, heating, curing, and treating, except where context
indicates otherwise.
[2062] Provided herein is an intelligent cooking system leveraging
hydrogen technology plus cloud-based value-added-services derived
from profiling, analytics, and the like. The smart hydrogen
technology cooking system provides a standardized framework
enabling other intelligent devices, such as smart-home devices and
IoT devices to connect to the platform to further enrich the
overall intelligence of contextual knowledge that enables providing
highly relevant value-added-services. The intelligent cooking
system device (referred to herein in some cases as the "cooktop"),
may be enabled with processing, communications, and other
information technology components and interfaces for enabling a
variety of features, benefits, and value added services including
ones based on user profiling, analytics, remote monitoring, remote
processing and control, and autonomous control. Interfaces that
allow machine-to-machine or user-to-machine communication with
other devices and the cloud (such as through application
programming interfaces) enables the cooking system to contribute
data that is valuable for analytics (e.g., on users of the cooking
system and on various consumer, commercial and industrial processes
that involve the cooking system), as well as for monitoring,
control and operation of other devices and systems. Through similar
interfaces, the monitoring, control and/or operation of the cooking
system, and its various capabilities, can benefit from or be based
on data received from other devices (e.g., IoT devices) and from
other data sources, such as from the cloud. For example, the
cooking system may track its usage, such as to determine when to
send a signal for refueling the cooking system itself, to send a
signal for re-supplying one or more ingredients, components or
materials (such as based on detected patterns of usage of the same
over time periods), to determine and provide guidance on usage of
the cooking system (such as to suggest training or improvements in
usage to improve efficiency or efficacy), and the like. These may
include results based on applying machine learning to the use of
the fuel, the use of the cooking system, or the like.
[2063] In embodiments, the intelligent cooking system may be fueled
by a hydrogen generator, referred to herein in some cases as the
electrolyzer, an independent fuel source that does not require
traditional connections to the electrical power grid, to sources of
gas (e.g., natural gas lines), or to periodic sources of supply of
conventional fuels (such as refueling oil, propane, diesel, or
other fuel tanks) The electrolyzer may operate on a water source to
separate hydrogen and oxygen components and subsequently provide
the hydrogen component as a source of fuel, such as an on-demand
source of fuel, for the intelligent cooking system. In embodiments,
the electrolyzer may be powered by a renewable energy source, such
as a solar power source, a wind power source, a hydropower source,
or the like, thereby providing complete independence from the need
for traditional power infrastructure. Methods and systems
describing the design, manufacturing, assembly, deployment, and use
of an electrolyzer are included herein. Among other benefits, the
electrolyzer allows storage of water, rather than flammable
materials like oil, propane, and diesel, as a source of energy for
powering cooking systems in various isolated or sensitive
industrial environments, such as on or in ships, submarines,
drilling platforms, mining environments, pipeline environments,
exploration environments, agricultural environments, clean room
environments, air- and space-craft environments, and others.
Intelligent features of the cooking system can include control of
the electrolyzer, such as remote and/or autonomous control, such as
to provide a precise amount of hydrogen fuel (converted from water)
at the exact point and time it is required. In embodiments,
mechanisms may be provided for capturing and returning products of
the electrolyzer, such as to return any unused hydrogen and oxygen
into water form (or directing them for other use, such as using
them as a source of oxygen for breathing).
[2064] Methods and systems describing the design, manufacturing,
assembly, deployment, and use of a smart hydrogen-based cooking
system are included herein. Processing hardware and software
modules for operating various capabilities of the cooking system
may be distributed, such as having modules or components that are
located in sub-systems of the cooking system (e.g., the burners or
other heating elements, temperature controls, or the like), having
modules or components located in proximity to a user interface for
the cooking system (e.g., associated with a control panel), having
modules or components located in proximity to a communications port
for the cooking system (e.g., an integrated wireless access point,
cellular communications chip, or the like, or a docking port for a
communications devices, such as a smart phone), having modules or
components located in nearby devices, such as other smart devices
(e.g., a NEST.RTM. thermostat), gateways, access points, beacons,
or the like, and/or having modules or components located on
servers, such as in the cloud or in a hosted remote control
facility.
[2065] In embodiments, the cooking system may have a mobile docking
facility, such as for docking a smart phone or other control device
(such as a specialized device used in an industrial process, such
as a processor-enabled tool or piece of equipment), which may
include power for charging the smart phone or other device, as well
as data communications between the cooking system and the smart
phone, such as to allow the smart phone to be used (such as via an
app, browser feature, or control feature of the phone) as a
controller for the cooking system.
[2066] In embodiments, the cooking system may include various
hardware components, which may include associated sensors for
monitoring operation, processing and data storage capabilities, and
communication capabilities. The hardware components may include one
or more burners or heating elements, (e.g., gas burners, electric
burners, induction burners, convection elements, grilling elements,
radiative elements, and the like), one or more fuel conduits, one
or more level indicators for indicating fuel level, one or more
safety detectors (such as gas leak detectors, temperature sensors,
smoke detectors, or the like). In embodiments, a gas burner may
include an on-demand gas-LPG hybrid burner, which can burn
conventional fuel like liquid propane, but which can also burn fuel
generated on demand, such as hydrogen produced by the electrolyzer.
In embodiments, the burner may be a consumer cooktop burner having
an appropriate power capability, such as being able to produce
20,000 British Thermal Unit ("BTU").
[2067] In embodiments, the cooking system may include a user
interface that facilitates intuitive, contextual,
intelligence-driven, and personalized experience, embodied in a
dashboard, wizard, application interface (optionally including or
integrating with one more associated smartphone tablet or
browser-based applications or interfaces for one or more IoT
devices), control panel, touch screen display, or the like. The
user interface may include distributed components as described
above for other software and hardware components. The application
interface may include interface elements appropriate for cooking
foods (such are recipes) or for using the cooking system for
various consumer, commercial or industrial processes (such as
recipes for making semi-conductor elements, for curing a coating or
injection mold, and many others).
[2068] Methods and systems describing the design, manufacturing,
assembly, deployment and use of a solar-powered hydrogen production
facility in conjunction with a hydrogen-based cooking system are
included herein.
[2069] Methods and systems describing the design, manufacturing,
assembly, deployment and use of a commercial hydrogen-based cooking
system that is suitable for use in a range of restaurants,
cafeterias, mobile kitchens, and the like are included herein.
[2070] Methods and systems describing the design, manufacturing,
assembly, deployment and use of an industrial hydrogen-based
cooking system that is suitable for use as a food cooking system in
various isolated industrial environments are included herein.
[2071] Methods and systems describing the design, manufacturing,
assembly, deployment and use of an industrial hydrogen-based
cooking system that is suitable for use as a heating, drying,
curing, treating or other cooking system in various industrial
environments are included herein, such as for manufacturing and
treating components and materials in industrial production
processes, including automated, robotic processes that may include
system elements that connect and coordinate with the intelligent
cooking system, including in machine-to-machine configurations that
enable application of machine learning to the system.
[2072] Methods and systems describing the design, manufacturing,
assembly, deployment and use of a low-pressure hydrogen storage
system are described herein. The low-pressure hydrogen storage
system may be combined with solar-powered hydrogen generation. In
embodiments, the cooking system may receive fuel from the
low-pressure hydrogen storage tank, which may safely store hydrogen
produced by the electrolyzer. In embodiments, the hydrogen may be
used immediately upon completion of electrolyzing, such that no or
almost no hydrogen fuel needs to be stored.
[2073] Methods and systems describing the architecture, design, and
implementation of a cloud-based platform for providing
value-added-services derived from profiling, analytics, and the
like in conjunction with a smart hydrogen-based cooking system are
included herein. The cloud-based platform may further provide
communications, synchronization among smart-home devices and third
parties, security of electronic transactions and data, and the
like. In embodiments, the cooking system may comprise a connection
to a smart home, including to one or more gateways, hubs, or the
like, or to one or more IoT devices. The cooking system may itself
comprise a hub or gateway for other IoT devices, for home
automation functions, commercial automation functions, industrial
automation functions, or the like.
[2074] Methods and systems describing an intelligent user interface
for a cloud-based platform for providing value-added services
("VAS") in conjunction with a smart hydrogen-based cooking system
are included herein. The intelligent user interface may comprise an
electronic wizard that may provide a contextual and intelligence
driven personalized experience dashboard for computing devices that
connect to a smart-home network or a commercial or industrial
network based around the smart hydrogen-based cooking system. The
architecture, design and implementation of the platform may be
described herein.
[2075] Methods and systems for configuring, deploying, and
providing value added services via a cloud-based platform that
operates in conjunction with a smart hydrogen-based cooking system
and a plurality of interconnected devices (e.g., mobile devices,
Internet servers, and the like) to prepare profiling, analytics,
intelligence, and the like for the VAS are described herein. In
embodiments, the cooking system may include various VAS, such as
ones delivered by a cloud-based platform and/or other IoT devices.
For example, among many possibilities, the cooking system may
provide recipes, allow ordering of ingredients, components or
materials, track usage of ingredients to prompt re-orders, allow
feedback on recipes, provide recommendations for recipes (including
based on other users, such as using collaborative filtering),
provide guidance on operation, or the like. The architecture,
design, and implementation of these methods and systems and of the
value-added-services themselves may further be described
herein.
[2076] In embodiments, through a user interface, such as a wizard,
various benefits, features, and services may be enabled, such as
various cooking system utilities (e.g., a liquid propane gas gauge
utility, a cooking assistance utility, a detector utility (such as
for leakage, overheating, or smoke, or the like), a remote control
utility, or the like). Services for shopping (e.g., a shopping cart
or food ordering service), for health (such as providing health
indices for foods, and personalized suggestions and
recommendations), for infotainment (such as playing music, videos
or podcasts while cooking), for nutrition (such as providing
personalized nutrition information, nutritional search
capabilities, or the like) and shadow cooking (such as providing
remote materials on how to cook, as well as enabling broadcasting
of the user, such as in a personalized cooking channel that is
broadcast from the cooking system, or the like).
[2077] Methods and systems for profiling, analytics, and
intelligence related to deployment, use, and service of a plurality
of hydrogen-based cooking systems that are deployed in a range of
environments including urban, rural, commercial, and industrial
settings are described herein. Urban settings may include rural
villages, low cost housing arrangements, apartments, housing
projects, and the like where several end users (e.g., individual
households, common kitchens, and the like) may be physically
proximal (e.g., apartments in a building, and the like). The
physical proximity can facilitate shared access to platform
components, such as a hydrolyser or low pressure stored hydrogen,
and the like. To the extent that individual cooktop deployments may
communicate through local or Internet-based network access,
additional benefits arise around topics such as, planning for
demand loading, and the like. An example may include generating and
storing more hydrogen during the week when people tend to cook a
home than on the weekend, or using shared information about recipes
to facilitate bulk delivery of fresh items to an apartment
building, multiple proximal restaurants, and the like. In
embodiments, the cooking system may enable and benefit from
analytics, such as for profiling, recording or analyzing users,
usage of the device, maintenance and repair histories, patterns
relating to problems or faults, energy usage patterns, cooking
patterns, and the like.
[2078] These methods and systems may further perform profiling,
analytics, and intelligence related to deployment, use and service
of solar-powered electrolyzers that generate hydrogen that is
stored in a low-pressure hydrogen storage system.
[2079] Methods and systems related to extending the capabilities
and access to content and/or VAS of a smart hydrogen-based cooking
system through intelligent networking and development of
transaction channels are described herein.
[2080] Methods and systems of an ecosystem based around the methods
and systems of generating hydrogen via solar-powered electrolyzers,
storing the generated hydrogen in low pressure storage systems,
distribution and use of the stored hydrogen by one or more
individuals, and the like, are described herein. In embodiments,
the cooking system, or a collection of cooking systems, may provide
information to a broader business ecosystem, such as informing
suppliers of foods or other materials or components of aggregate
information about usage, informing advertisers, managers and
manufacturers about consumption patterns, and the like.
Accordingly, the cooking system may comprise a component of a
business ecosystem that includes various parties that provide
various commodities, information, and devices.
[2081] Another embodiment of smart cooking technology described
herein may include an intelligent, computerized knob or dial
suitable for direct use with any of the cooking systems, probes,
single burner and other heating elements, and the like described
herein. Such a smart knob or dial may include all electronics and
power necessary for independent operation and control of the smart
systems described herein.
[2082] In embodiments, the cooking system is an industrial cooking
system used to provide heat in a manufacturing process. In
embodiments, the industrial cooking system is used in at least one
of a semi-conductor manufacturing process, a coating process, a
molding process, a tooling process, an extrusion process, a
pharmaceutical manufacturing process and an industrial food
manufacturing process.
[2083] In embodiments, a smart knob is adapted to store
instructions for a plurality of different cooking systems. In
embodiments, a smart knob is configured to initiate a handshake
with a cooking system based on which the knob automatically
determines which instructions should be used to control the cooking
system. In embodiments, a smart knob is configured with a machine
learning facility that is configured to improve the control of the
cooking system by the smart knob over a period of use based on
feedback from at least one user of the cooking system.
[2084] In embodiments, a smart knob is configured to initiate a
handshake with a cooking system to access at least one value-added
service based on a profile of a user.
DETAILED DESCRIPTION
[2085] Referring to FIG. 226, an integrated cooktop embodiment 11
of the intelligent cooking system methods and systems 21 described
herein is depicted. The cooktop embodiment 11 of FIG. 226, may
include one or more burners 31 that may burn one or more types of
fuel, such as Liquid Propane Gas (LPG), hydrogen, a combination
thereof, and the like. Gas burners may, for example, be rated to
provide variable heat, including up to a maximum heat, thereby
consuming a corresponding amount of fuel. One or more of the
burners 31 may operate with an LPG source 51 and a source of
hydrogen gas 61 such that the hydrogen source 61 may be utilized
based on a demand for fuel indicated by the burner 31, a measure of
available LPG fuel, an amount of LPG fuel used over time, and any
combination of use, demand, historical usage, anticipated usage,
availability of supply, weather conditions, calendar date/time
(e.g., time of day, week, month, year, and the like), proximity to
an event (e.g., an intense cooking time, such as just before a
holiday), and the like. The hydrogen source 61 may be utilized so
that the amount of other fuel used, such as LPG, is kept below a
usage threshold. Such a usage threshold may be based on costs of
LPG gas, uses of LPG gas by other burners 31 in the cooking system
21, other cooking systems 21 in the vicinity (e.g., other cooking
systems 21 in a restaurant, other cooking systems 21 in nearby
residences), and the like. Each cooking system 21 and/or burner 31
within the cooking system 21 may therefore provide on-demand fuel
sourcing dynamically without need for user input or monitoring of
the cooking system 21. By automating fuel sourcing, the burner may
extend the life of available LPG by automatically introducing the
hydrogen fuel, such as by switching from one source to the other or
by reducing one source (e.g., LPG) while increasing the other
(e.g., hydrogen). The degree to which each fuel source is utilized
may be based on a set of operational rules that target efficiency,
LPG fuel consumption, availability of hydrogen, and the like.
Rating of the one or more burners 31 may be under the control of a
processor, including to provide different levels of rating for
different fuel sources, such as LPG alone, hydrogen alone, or a
mixture of LPG and hydrogen with a given ratio of constituent
parts.
[2086] Each of the burners 31, cooking systems 21, or collection of
cooking systems 21 may be configured with fuel controls, such as
fuel mixing devices (e.g., valves, shunts, mixing chambers,
pressure compensation baffles, check valves, and the like) that may
be controlled automatically based, at least in part on some measure
of historical, current, planned, and/or anticipated consumption,
availability, and the like. In an example, one or more burners 31
may be set to produce 1000 W of heat and a burner gas source
control facility may activate one or more gas mixing devices while
monitoring burner output to ensure that the burner output does not
deviate from the output setting by more than a predefined
tolerance, such as 100 W or ten percent (10%). Alternatively, a
model of gas consumption and burner output, embodied in a software
module that may have access to data sources regarding types of gas,
burning characteristics, types of burners, rating characteristics,
and the like, may be used by the control facility to regulate the
flow of one or more of gasses being mixed to deliver a consistent
burner heat output. Any combination of burner output sensing,
modeling, and preset mixing control may be used by the control
facility when operating fuel sourcing and/or mixing devices.
[2087] The one or more burners 31 may include intelligence for
enhancing operation, efficiency, fuel conservation, and the like.
Each of the burners 31 may have its own control facility 101. A
centralized cooking system control facility may be configured to
manage operation of the burners 31 of the cooking system 21 or
other heating elements noted throughout this disclosure.
Alternatively, the individual burner control facilities 101 may
communicate over a wired and/or wireless interface to facilitate
combined cooking system burner control. One or more sensors to
detect presence of an object in the targeted heating zone (e.g.,
disposed on the burner grate) may provide feedback to the control
facility. Object presence sensors may also provide an indication of
the type, size, density, material, and other aspect of the detected
object in the targeted heating zone. Detection of a material such
as metal, versus cloth (e.g., a person's sleeve), versus human
flesh may facilitate efficiency and safety. When cloth or human
flesh is detected, the control facility may inhibit heat production
so as to avoid burning the person's skin or causing their clothing
to catch fire. Such a control facility safety feature may be over
ridden through user input to the control facility to give the user
an opportunity to determine if the inhibited operation is proper.
Other detectors, such as spill over (e.g., moisture) detectors in
proximity to the burner may help in managing safety and operation.
A large amount of spillage from a pot may cause the flame being
produced by the burner to be extinguished. Based on operational
rules, the source of gas may be disabled and/or an igniter may be
activated to resume proper operation of the burner. Other actions
may also be configured into the control facility, such as signaling
the condition to a user (e.g., through an indicator on the cooking
system 21, via connection to a personal mobile device, to a central
fire control facility, and the like).
[2088] Burner control facilities 101 may control burner heat output
(and thereby control fuel consumption) based on one or more models
of operation, such as to heat a pan, pot, component, material, or
other item placed in proximity to the burner 21 or other heating
element. As an example, if a user wants to boil water in a heavy
metal pot quickly, a control facility may cause a burner to produce
maximum heat. Based on user preferences and/or other factors as
noted above related to demand, supply, and the like, the control
facility may adjust the burner output while notifying the user of a
target time for completion of a heating activity (e.g., time until
the water in the pot boils). In this way an intelligent burner 21
(e.g., on with a burner control facility) may achieve some user
preferences (e.g., heating temperature) while compromising on
others (e.g., amount of time to boiling, and the like). The
parameters (e.g., operational rules) for such tradeoff may be
configured into the cooking system 21/burner 31 during production,
may be adjustable by the user directly or remotely, may be
responsive to changing conditions, and the like. In embodiments,
machine learning, either embodied at the cooking system 21, in the
cloud, or in a combination, may be used to optimize the parameters
for given objectives sought by users, such as cooking time, quality
of the result (e.g., based on feedback measures about the output
product, such as taste in the case of foods or other quality
metrics in the case of other products of materials). For example,
the cooking system 21 may be configured under control of machine
learning to try different heating patterns for a food and to
solicit user input as to the quality of the resulting item, so that
over time an optimal heating pattern is developed.
[2089] The intelligent cooking system 21 as described herein and
depicted in FIG. 226 may include an interface port 127 with
supporting structural elements to securely hold a personal mobile
device 150 (e.g., a mobile phone) in a safe and readily viewable
position so that the user may have both visual and at least
auditory access to the device. The cooking system 21 may include
features that further ensure that the mounted mobile device 150 is
not subject to excessive heat, such as heat shields, deflectors,
air flow baffles, heat sinks, and the like. A source of airflow may
be incorporated to facilitate moving at least a portion of heated
air from one or more of the burners 31 away from a mounted personal
mobile device 150.
[2090] The intelligent burner embodiment 280 depicted in FIG. 227
represents a single burner embodiment 210 of the intelligent
cooking system 21 described herein. Any, none, or all features of a
multi-burner intelligent cooking system 21 may be configured with
the single burner version depicted in FIG. 227. Further depicted in
FIG. 227 is a version of the intelligent burner 280 that may have
an enclosed burner chamber 220 that provides heat in a target
heat-zone as a plane of heat rather than as a volume of heat. This
may be generated by induction, electricity, or the like that may be
produced by converting a source of fuel, such as LPG and/or
hydrogen with a device that may produce electricity from a
combustible gas.
[2091] The intelligent cooking system 21 may be combined with a
hydrogen generator 300 to provide a source of hydrogen for use with
the burners 31 as described herein. FIG. 228 depicts a
solar-powered hydrogen production and storage station 320. The
hydrogen production station 320 may be configured with one or more
solar collectors 330, such as sunlight-to-electricity conversion
panels 340 that may produce energy for operating an electrolyzer
350 that converts a hydrogen source, such as water vapor, to at
least hydrogen and oxygen for storage. Energy from the solar
collectors 330 may power one or more electrolyzers 350, such as one
depicted in the embodiment 700 of FIG. 232. The one or more
electrolyzers 350 may process water vapor, such as may be available
in ambient air, for storage in a storage system 360, such as a
low-pressure storage system 370 depicted in FIG. 228.
Alternatively, and/or in addition to processing air-born water
vapor, a source of water, such as collected rainfall, public water
supply, or other source may be processed by the electrolyzer 350 to
produce hydrogen fuel.
[2092] As hydrogen fuel is produced, it may be stored in a suitable
storage container, such as the low-pressure storage system 370 that
may be configured with the solar-powered electrolyzer system 350.
The hydrogen produced by the solar-powered electrolyzer 350 may be
routed to one or more intelligent cooking systems 21 in addition to
or in place of being routed to a storage system 360. A hydrogen
production and storage system 320 may produce hydrogen based on a
variety of conditions including, without limitation, availability
of a source of water vapor, availability of power to the
electrolyzer, an amount of sunlight being collected, a forecast of
sunlight, a demand for hydrogen energy, a prediction of demand,
based on availability of LPG, usage of LPG, and the like.
[2093] The low-pressure gas storage system 370 may store the
hydrogen and oxygen in ultraviolet ("UV") coated plastic bags or
through water immersion technology (e.g., biogas). The maximum
pressure inside the system may be less than 1.1 bar, which promotes
safety, as the pressure is very low. Also, as no compressors are
used, the cost for storage is much lower than for active storage
systems that store compressed gas. FIG. 229, FIG. 230, and FIG. 231
depict an embodiment 400 of such a low-pressure storage system 370,
with an inlet valve 411 and outlet valve 413 providing ports into
an interior storage area 415 with the internal volume separated
into two parts.
[2094] The low pressure set up may directly work from renewable
energy, such as solar energy collected by solar cells, wind energy,
hydro-power, or the like, improving the efficiency. The selected
source of renewable energy may be based on characteristics of the
environment; for example, marine industrial environments may have
available wind and hydro-power, agricultural environments may have
solar power, etc. Also if the renewable energy (e.g. solar energy)
collection facility is connected to a power grid, the electricity
generated and the energy stored may be provided to the grid, e.g.,
during high cost periods. Likewise, the grid may be used to restore
any used energy during off peak hours at reduced costs.
[2095] The designed low-pressure storage may be used to store
hydrogen, as a source of energy, that may be converted into
electricity. The designed system may store energy at very low cost
and may have a lifetime of years, e.g., more than 15 years, which
modern batteries don't have. Amounts of storage may be configured
to satisfy safety requirements, such as storing little enough to
cause a minimal fire hazard as compared to storing larger amounts
of other fuels.
[2096] In an embodiment, the intelligent cooking system 21 may
signal to the electrolyzer system 350 a demand for hydrogen fuel.
In response, the electrolyzer system 350 may direct stored hydrogen
to the cooking system 21, begin to produce hydrogen, or indicate
that hydrogen is not currently available. This response may be
based, at least in part on conditions for producing hydrogen. If
conditions for producing hydrogen are good, the electrolyzer system
may begin to produce hydrogen fuel rather than merely sourcing it
from storage. In this way, the contemporaneous demand for hydrogen
fuel and an ability to produce it may be combined to determine the
operation of the energy production and consumption systems.
[2097] The intelligent cooking system 21 and/or hydrogen production
and storage systems described herein may be combined with a
platform that interacts with electronic devices and participants in
a related ecosystem of suppliers, content providers, service
providers, regulators, and the like to deliver VAS to users of the
intelligent cooking system 21, users of the hydrogen production
system, and other participants in the ecosystem. Certain features
of such a platform 800 may be depicted in FIG. 233. The platform
800, which may be a cloud-based platform, may handle cooking system
utilities, such as leakage sensing, fuel sourcing, usage
assistance, remote control, and the like. In an example, a user who
is located remotely from the intelligent cooking system 21 may
configure the cooking system 21 to operate at a preset time, or
based on a preset condition from his/her computing device (e.g., a
personal mobile phone, desktop computer, laptop, tablet, and the
like). The user may further be notified when the cooking system 21
begins to operate, thereby ensuring the user that the cooking
system 21 is operating as expected. A user or third party (e.g., a
regulatory agency, landlord, and the like) may configure one or
more present conditions. Such conditions may include a variety of
triggers including time, location of a user or third party, and the
like. In an example, a parent may want to have a cooking system
operate to warm up ingredients based on an anticipated arrival of
someone to the home. This anticipation may be based on a detected
location of a mobile device being carried by a person whose arrival
is being anticipated.
[2098] The platform 800 may further connect cooking system users
with participants in the ecosystem (e.g., vendors and/or service
providers) synergistically so that both the user and the
participants may benefit from the platform 800. In an example, a
user may plan to prepare a meal for an upcoming dinner. The user
may provide the meal plan to the platform 800 (e.g., directly
through the user's mobile phone, via the user's intelligent cooking
system 21, and the like). The platform 800 may determine that fresh
produce for the meal is preferred by the user and may signal to
retailers and/or wholesalers to have the produce available for the
user to pick up on his/her return to the home to prepare the meal.
In this way, vendors and service providers who participate in the
ecosystem may gain insight into their customer's needs. Likewise,
users may indicate a preference for a type of meal that may be
prepared with a variety of proteins. Participants in the ecosystem
may make offers to the user to have one or more of the types of
protein available for the user on the day and at the time preferred
by the user. A butcher that is located in proximity to the user's
return path may offer conveniences, such as preparation of cuts of
meat for the user. Butchers who may not be conveniently located in
proximity to the user's return path may offer delivery services on
a day and time that best complies with the user's meal plans.
[2099] A user of such a platform-connected intelligent cooking
system may leverage the platform 800 to gain both access to and
analysis of information that is available across the Internet to
address particular user interests, such as health, nutrition, and
the like. As an example, a user may receive guidance from a health
professional to reduce red meat intake and increase his seafood
intake. The platform 800 may interact with the user, the cooking
system, and ecosystem participants to facilitate preparing
variations of a family's favorite meals with fish instead of red
meat. Changes in spices, amounts, cooking times, recipes, and the
like may be provided to the user and to the cooking system 21
through the platform 800 to make meal preparation more enjoyable.
The platform 800 may help with nutritional assistance, such as by
providing access to quality nutritional professionals who may work
personally with a user in meal selection and preparation.
[2100] The platform 800 may also help a user of the platform 800,
even one who does not have access to the intelligent cooking system
21, to benefit from the knowledge gathering and analysis possible
from a platform 800 interconnected with a plurality of cooking
systems, users, and ecosystem participants. In an example, the
platform 800 may provide guidance to a user in the selection and
purchase of an intelligent burner and/or integrated cooking system
and related appliances (e.g., refrigeration), utensils, cookware,
and the like.
[2101] The platform 800 may further facilitate integration with
VAS, such as financial services (e.g., for financing infrastructure
and operating costs), healthcare services (e.g., facilitating
connecting healthcare providers with patients at home), smart home
solutions (e.g., those described herein), rural solutions (e.g.,
access to products and services by users in rural jurisdictions),
and the like. Information (e.g., profiles, analytics, and the like)
gathered and/or generated by the platform 800 may be used for other
business services either directly with or through other partners
(e.g., credit rating agencies for developing markets).
[2102] The platform 800 may facilitate a range of user benefits,
including shopping, infotainment, business development, and the
like. In a business development example, a user may utilize her
intelligent integrated cooking system 21 to produce her own cooking
show by setting up her personal phone with camera on the cooking
system 21 so that the user activity on the cooking system 21 may be
captured and/or distributed to other users via the platform 800.
Further in the example, a user may schedule a cooking demonstration
and may allow other users to cook along with him in an autonomous
and/or interactive way. A user may opt into viewing and cooking
along with the cooking show producer without directly interacting
with the producer. Whereas, another user may configure his cooking
system 21 with a personal mobile device and allow others to provide
feedback based on the user's activities on the cooking system 21
via the camera and user interface of the mobile device.
[2103] The platform 800 may facilitate establishing an IoT
ecosystem of smart home devices, such as, in embodiments, a smart
kitchen that enables and empowers the homemaker. The smart kitchen
may include a smart cooking system 21, IoT middleware and a smart
kitchen application. The smart cooking system 21 may provide a
hardware layer of the platform 800 that may provide plug and play
support for IoT devices, with each new device acting as a node
providing more information, such as from additional sensors, to the
entire system. IoT cloud support, which may be considered as a
middleware layer of the platform 800, may enable the communication
(such as by streaming) and storage of data on the cloud, along with
enabling optional remote management of various capabilities the
platform 800. A smart kitchen application may include a user
interface layer that may provide a single point of access and
control for the entire range of smart devices for the ease of the
homemaker or other user. As an example of a smart kitchen enabled
by the smart cooktop methods and systems described herein, an
exhaust fan may be turned on as the water in a pot begins to boil,
thereby directing the steam output of the pot away from the
kitchen. This may be done through a combination of sensors (e.g., a
humidity sensor), automated cooking system control that determines
when the pot will begin to boil based on the weight of the pot on
the burner, and the energy level of the burner, and the like.
Similar embodiments may be used in industrial environments, such as
coordination with ventilation systems to maintain appropriate
temperature, pressure, and humidity conditions by coordination of
heating activities via the cooking system 21 and routing and
circulation of air and other fluids by the ventilation system. The
cooking system controller may, for example, communicate with an
exhaust fan controller to turn on the fan based on these inputs
and/or calculations; thereby improving the operation of the smart
kitchen appliances while conserving energy through timely
application of the exhaust fan. A flow chart representative of
operational steps S600 for this example is depicted in FIG.
281.
[2104] The value created by such a platform 800 may be broadly
classified into (i) VAS; (ii) profiling, learning and analytics;
and (iii) a smart home solution or IoT solution for a commercial or
industrial environment. The VAS of the system, may include without
limitation: (a) personalized nutrition; (b) information and
entertainment (also referred to as "infotainment"); (c) family
health; (d) finance and commerce services (including online
ordering and shopping); (e) hardware control services; and many
other types of services.
[2105] Profiling, learning and analytics may provide a number of
benefits to various entities. For example, a homemaker may get
access to personalized nutrition and fitness recommendations to
improve the health of the entire family, including healthy recipe
and diet recommendations, nutritional supplement recommendations,
workout and fitness recommendations, energy usage optimization
advice for cooking and use of other home appliances, and the like.
Device manufacturers and other enterprises may also benefit, as the
platform 800 may solve the problems faced by home appliance device
manufacturers in integrating their devices to the cloud and
leveraging the conveniences provided by the same. Device
manufacturers and other enterprises may be provided with an
interface to the platform 800 (such as by one or more application
programming interfaces, graphical user interfaces, or other
interfaces) that may enable them to leverage capabilities of the
platform 800, including, one or more machine learning algorithms or
other analytic capabilities that may learn and develop insights
from data generated by the device. These capabilities may include
an analytics dashboard for devices; a machine learning plug and
play interface for developing data insights; a health status check
for connected appliances (e.g., to know when a device turns faulty,
such as to facilitate quick and easy replacement/servicing); and
user profiling capabilities, such as to facilitate providing
recommendations to users, such as based on collaborative filtering
to group users with other similar users in order to provide
targeted advice, offers, advertisements, and the like.
[2106] A smart home solution or IoT solution for a commercial or
industrial environment may provide benefits to device manufacturers
who find it difficult to embed complex electronics in their devices
to make them intelligent due to development and cost constraints.
The platform 800 simplifies this by providing a communication layer
that may be used by partners to send their device data, after which
the platform 800 may take over and provide meaningful data and
insights by analyzing the data and performs specific actions on
behalf of an integrated smart home for the user. Additional value
of each partner interacting through the platform 800 is the access
to various sensory data built into the system for effectively
making any connected device more intelligent. For example, among
many possibilities, the ambient temperature sensor inside the smart
cooking system 21 may be leveraged by a controllable exhaust
facility to accordingly increase the airflow for the comfort of the
homemaker.
[2107] Referring to the smart home embodiment of FIG. 234, an
intelligent cooking system 900 may be a participant in or may be a
gateway to a home appliance network that may include other kitchen
appliances, sensors, monitors, user interface devices, processing
devices, and the like. The home appliance network, and/or the
devices configured in the home network, may be connected to each
other and to other participants of the ecosystem through the
platform 800 (FIG. 233). Data collected from these appliances,
participants in the ecosystem, users of the platform, third
parties, and the like may provide an interactive environment to
explore, visualize, and study patterns, such as fuel usage
patterns. Data collected may further be synthesized through deep
machine learning, pattern recognition, modeling, and prediction
analysis to provide valuable insights related to all aspects of the
platform participants, devices, suppliers, and the larger
ecosystem.
[2108] Further embodiments of the hydrogen generation and
consumption capabilities are now described.
[2109] The system may use water and electricity as fuel to generate
the gas-on-demand that may be used, for example, for cooking. The
hydrogen and oxygen generated in the cell may be separated out
within the cell and kept separate until reaching the combustion
port in a burner. A specially designed burner module may comprise
different chambers to allow passage of hydrogen, oxygen, and
cooking gas. The ports for hydrogen and cooking gas may be designed
in such a way as to avoid flame flashbacks and flame lift-offs, and
the like. The oxygen ports may be designed to ensure optimum supply
of oxygen with respect to the hydrogen supply. The hydrogen and
oxygen ports may be on mutually perpendicular planes ensuring
proper intermixing of the burning mixture. The hydrogen and cooking
gas connections may be mutually independent and may be operated
separately or together to generate a mixed flame.
[2110] A hydrogen production and use system 1000 as disclosed
herein may comprise one or more of the following elements as
depicted in FIGS. 235 and 236. An electrolytic cell 1101 is
detailed in FIG. 236, which shows an exploded view of the cell
consisting of steel electrodes separated by nylon membranes inside
polyvinyl chloride ("PVC") gaskets sandwiched by acrylic sheets.
The cell may comprise an alkaline electrolytic cell that separates
water into its constituent components of hydrogen and oxygen. A
mixture tank, such as a concentrated alkaline mixture tank may
serve as the electrolyte source for the electrolytic cell. The
alkali mixture may be prepared by mixing a base like potassium
hydroxide ("KOH") or sodium hydroxide ("NaOH") with water. In case
of KOH, in embodiments the concentration may be around 20%. The
membrane for separation of gases within the cell may be made from a
variety of materials. One such material is a nylon sheet with
catalyst coating that has enough thread count to allow ion transfer
and minimal gas transfer. The electrodes used may be, for example,
stainless steel or nickel coated stainless steel. Also provided may
be gas bubbling tanks. The hydrogen and oxygen generated from the
electrolytic cells may be passed through gas bubbling tanks. The
tanks may be made with recirculation or non-recirculation modes. In
a non-recirculation mode, the gas is bubbled through water and any
impurity in the gas gets purified in the process. In recirculation
mode, the gas is bubbled through KOH solution, which may be
identical in concentration to the alkaline mixture tank. In this
methodology, any additional electrolyte that flows out with the gas
gets re-circulated into the alkaline mixture tank. The two bubbling
tanks may be connected together, such as at the bottom, to ensure
pressure maintenance across them. Dehumidifiers may also be
included. The gas passed through the bubblers may have excess
moisture content that reduces the combustion efficiency. Hence, the
gas may be passed through dehumidifiers, which may use a desicmayt,
water-gas separator membranes, or other dehumidification
technologies, or a combination thereof, to reduce the humidity
content of the gas. A hydrogen burner arrangement is provided
wherein a conventional hydrogen burner, as known in the art, may be
connected to the dehumidifier, such as through a flashback
arrestor. In embodiments, there are no ports for air intake, as
combustion of the hydrogen-air mixture may result in an elevated
concentration of mono-nitrogen oxides ("NOx"), which in turn may
result in a potential for flame flashback. The burner ports may
have a small diameter, such as lower than 0.5 mm, to reduce the
chance of any flame flashback. The ports may be aligned in such a
way as to cross-ignite, resulting in combustion of the complete gas
supply with a single spark. The hydrogen concentration throughout
the supply line may be above the maximum combustion limit, and
hence there is little safety hazard. The oxygen supply may be
through a channel that is completely separate from the hydrogen
one. The oxygen ports may be located on a plane perpendicular to
the hydrogen ports to ensure proper mixing of the combustion
mixture. Above the burner, a catalyst may be placed so as to lower
the temperature of combustion, reducing the concentration of NOx
generated. An economically feasible high temperature catalyst mesh
may be used to lower the temperatures of combustion.
[2111] The power supply may supply a desired voltage that may be
optimized according to the conditions of the system, such as the
water temperature, pressure, etc. The voltage per cell may vary,
such as from 1.4 v to 2.3 v, and the current density may be as low
as 44 mA/cm.sup.2 for maximum efficiency. As the current density is
low, the efficiency tends to be high.
[2112] An LPG/cooking gas burner arrangement may be provided. The
LPG/cooking gas burner arrangement may be added to the hydrogen
burner arrangement. In embodiments, the system may be similar to a
closed top burner arrangement, where the burner ports are along the
sides of the burner and the flame fueled by the LPG surrounds the
hydrogen flame. In embodiments, the gas supply channel may be kept
separate from the hydrogen supply channel and the oxygen supply
channel and would hence pose no safety risk in that regard. In
alternative embodiments, the fuels may be mixed, such as under
control of a processor.
[2113] A renewable energy connection may be provided. In
embodiments, the whole system, including the storage system, may be
connected to renewable energy sources like solar power, wind power,
water power, or the like. The hydrogen storage may act as storage
for energy produced by such a renewable energy source.
[2114] In yet another embodiment of the system, the actuation of
the combustion may be done using a sensor placed along the oxygen
supply channel to detect the presence of a cooking utensil on the
burner. The sensor may be shielded from the heat and made to work
at an optimum temperature.
[2115] In yet another embodiment of the system, the hydrogen flame
may be used to heat a coil that could hence radiate heat for more
spread out cooking. The hydrogen supply to the radiator may be
regulated by the temperature within the radiator.
[2116] In yet another embodiment of the system, the heat absorbed
by the catalyst mesh may be used to generate electric power,
increasing the net efficiency of the system.
[2117] The hydrogen production system may be integrated into a
cooking system 1201 as depicted in FIG. 237, which may include
smart cooking system comprising a microcontroller with basic
sensors, such as gyro, accelerometer, temperature and humidity.
Other sensors like weight, additional temperature sensors, pressure
sensors, and the like may be mounted on the cooking system and,
based upon various inputs from the user and the system (including
optional remote control), the actuators may control the cooking
temperature, time and other cooking functions.
[2118] A speaker may sometimes be used to read out the output or
simply play music.
[2119] The microcontroller may also be interfaced with a display
and touch interface.
[2120] The microcontroller may be connected with the cloud, where
information regarding recipes, weight and temperature, and the like
may be stored and accessed by the controller. The microcontroller
may also provide information on the user's cooking patterns.
[2121] In an embodiment, smart system configuration, control, and
cooking algorithms may be executed by computers (e.g., in the
cloud) to process all gathered and sensed information, optionally
providing a recommendation related to the operation to the end
user. The recommendation may include suggesting suitable recipes,
auto turning of the heat in the burner, and the like. The
microcontroller may communicate via Bluetooth low energy ("BLE"),
Wi-Fi and/or lowaran, or the like, such as to ensure connectivity
to the cloud. Lowaran is a wireless network that leverages
long-range radio signals for communicating between IoT devices and
cloud devices via a central server. The microcontroller may be
designed in such a way that it has enough processing power to
connect to other IoT devices that may have little or no processing
power and also do processing for these IoT devices to give the end
user a smart and intelligent, all in one, smart home solution.
[2122] FIG. 238 and FIG. 239 depict auto-switching connectivity
1301 in the form of ad hoc Wi-Fi from a cooktop 1310 through nearby
mobile devices 1371 may be performed in the event of
non-availability of a common home Wi-Fi router 1340 to ensure cloud
connectivity 1360 whenever possible. FIG. 238 depicts a normal
connectivity mode when Wi-Fi 1340 is available. FIG. 239 depicts ad
hoc use of local mobile devices 1400 for connectivity to the cloud
1360.
[2123] Additional smart cooking system features and capabilities
may include weight sensors for each heating element that, when
combined with cooking learning algorithms, may control fuel
consumption to minimize overcooking and waste of fuel. This may
also benefit configurations that employ multiple heating elements,
so that unused heating elements do not continue to operate and
waste fuel. FIG. 240 depicts a three-element induction smart
cooking system 1500. Heating elements may be gas-based or may
alternatively include heating with induction, electric hot plate,
electric coil, halogen lamp, and the like. FIG. 241 depicts a
single burner gas smart cooking system 1600. FIG. 242 depicts an
electric hot plate (coil) smart cooking system 1700. FIG. 243
depicts a single induction heating element smart cooking system
1800.
[2124] Another embodiment of smart cooking technology described
herein may be an intelligent, computerized knob, dial, slider, or
the like suitable for direct use with any of the cooktops, probes,
single burner elements, and the like described herein. Such a smart
knob 2000 may include all electronics and power necessary for
independent operation and control of the smart systems described
herein. References to a smart knob 2000 should be understood to
encompass knobs, dials, sliders, toggles and other physical user
interface form factors that are conventionally used to control
temperature, timing and other factors involved in heating, cooking,
and the like, where any of the foregoing are embodied with a
processor and one or more other intelligent features.
[2125] The smart knob 2000 may include an embodiment with a digital
actuator, such as for electric-based cooking systems and another
embodiment with a mechanical actuator, such as for gas models. The
smart knob 2000 may be designed with portability and functionality
in mind. The knob may include a user interface (e.g., display,
audio output, and the like) through which it may provide users
step-by-step recipes, and the like. The smart knob 2000 may operate
wirelessly, so that it may set alarms and also monitor the
operation of a plurality of smart cooking systems 21 even if it is
removed from the cooking system actuator. The smart knob 2000 may,
in embodiments, store information that allows it to interface with
different kinds of cooking systems, such as by including programs
and instructions for forming a handshake (e.g., by Bluetooth.TM. or
the like) with a cooking system to determine what control protocol
should be used for the cooking system, such as one that may be
managed remotely, such as in a cloud or other distributed computing
platform. In embodiments, a user may bring the smart knob 2000 in
proximity to the cooking system 21, in which case a handshake may
be initiated (either under user control or automatically), such
that the smart knob 2000 may recognize the cooking system 21 and
either initiate control based on stored instructions on the knob
2000 or initiate a download of appropriate programming and control
instructions for the cooking system 21 from a remote source, such
as a cloud or other distributed computing platform to which the
knob 2000 is connected. Thus, the knob 2000 serves as a universal
remote controller for a variety of cooking systems, where a user
may initiate control using familiar motions, such as turning a dial
to set a timer or temperature setting, moving a toggle or slider up
or down, setting a timer, or the like. In embodiments, a plurality
of knobs 2000 may be provided that coordinate with each other to
control a single burner or heating element or a collection of
burners or heating elements. For example, one of the knobs 2000 in
a pair of knobs might control temperature of a burner or heating
element, while a second knob in the pair might control timing for
the heating.
[2126] In embodiments, the smart knob 2000 may be used to embody
complex protocols, such as patterns of temperatures over time, such
as suitable for heating an item to different temperatures over
time. These may be stored as recipes, or the like, so that a user
may simply indicate, via the knob 2000, the desired recipe, and the
knob 2000 will automatically initiate control of a burner or
heating element to follow the recipe.
[2127] A user may use the smart knob 2000 with an induction cooking
system for controlling the temperature of a cooking system, such as
an induction stove, providing step-by-step instructions, and the
like. The user may, for example, switch to cooking with a gas
burner-based smart cooking system by simply taking the smart knob
2000 off of the induction cooking system, configuring it to operate
the gas burner cooking system (such as by initiating an automated
handshake), and mounting the knob 2000 in a convenient place, such
as countertop, wall, refrigerator door, and the like. It should be
noted that while the knob 2000 may be placed on the cooking system,
once a connection has been established, such as by Bluetooth.TM.,
near-field communication ("NFC"), Wi-Fi, or by programming, the
knob 2000 may be placed at any convenient location, such as on the
person of a user (such as where a user is moving from place to
place in an industrial environment), on a dashboard or other
control system that controls multiple devices, or on another
object. The knob 2000 may be provided with alternative interfaces
for being disposed, such as clips for attachment to objects,
hook-and-loop fasteners, magnetic fasteners, and physical
connectors.
[2128] The smart knob 2000 may use, include or control the various
features of the smart cooking systems 21 described throughout this
disclosure. Additionally, the smart knob 2000 may be connected to
other IoT devices, such as smart doorbell, remote temperature probe
(e.g., in a refrigerator or freezer), and the like. The smart knob
2000 may be used for kitchen tasks other than cooking. By
connecting with a temperature probe, the smart knob 2000 may be
used to inform a user of the progress of an item placed in the
refrigerator or freezer to cool down.
[2129] As it requires only very little power and as it is mountable
on the smart cooking system 21, the smart knob 2000 may, in
embodiments, be recharged through thermoelectric conversion of the
heat from a burner on the cooking system 21, so that the use of
external power supply is not required.
[2130] FIGS. 244-251 depict a variety of user interface features
2010, 2020, 2101, 2201, 2300, 2400, 2500, 2600 of the smart knob
2000.
[2131] FIG. 252 depicts a smart knob 2700 deployed on a single
heating element cooking system 2710, while FIG. 253 depicts a smart
knob 2800 placed on a side of a kitchen appliance 2810.
[2132] Other features of a smart cooking system 21 may include
examples of smart temperature probes 3101 depicted in FIGS.
254-257. The temperature probe 3101 may consist of a wired or
wireless temperature sensor that may be interfaced with a smart
cooking system 21, smart knob 2000, and/or a mobile phone 150 for
cooking. The temperature probe 3101 may, in embodiments, be dipped
into a liquid (such as a soup, etc.) or inserted interior of a
solid (such as a piece of meat or a cooking baked good), to cook
very precisely based on the measured interior temperature of the
liquid or solid. Also the smart temperature probe 3101 may
facilitate use of an induction base to control the temperature of
the base for heating water to a precise temperature (e.g., for tea)
with any type of non-magnetic cooking vessel.
[2133] The smart cooking system 21 may include a smart phone
docking station 3301 that may be configured to prevent cooking heat
from directly impacting a device in the station while facilitating
easy access to the phone for docking, undocking and viewing. A
variety of different docks 3310, 3401, 3501, 3601, 3701, 3801 for
compatibility with a range of smart phone and tablet devices are
depicted in FIGS. 258-263.
[2134] Various burner designs are contemplated for use with a smart
cooking system as described herein. FIGS. 264-280 depict exemplary
burners 3900, 4200, 4701, 5000, 5300.
[2135] The Internet-connected smart cooking system 21 described
herein may include tools and features that may help a user, such as
a homemaker, a commercial chef, or cook in an industrial
environment to prepare healthier meals, learn about food choices of
other users, facilitate reduced meal preparation time, and
repeatable cooking for improved quality and value. A few
applications that may leverage the capabilities of the present
Internet-connected smart cooktop may include a fitness application
that helps one estimate daily calorie consumption requirements for
each member of a user's family or other person for whom the user
may prepare meals. This may help a user to control and track the
user's family fitness over time. Using data from recipes and weight
sensors for pots/pans used to cook the food for the recipes, a
fitness application may generate a calorie consumption estimate and
suggest one or more healthy alternative recipes. Through combining
sensing and control of the cooktop functionality (e.g., burners)
with Internet access to food nutrition and weight values for recipe
ingredients being cooked, the calorie count of a content of a pan
placed on a smart cooktop burner may be estimated. As an example,
if a recipe calls for 1/4 cup of lentils per serving combined with
a serving-unit of water, a total weight of a pan being used to
prepare the lentils may be sensed. By knowing the weight of the
pan, a net weight of the ingredients in the pan may be calculated
so that a number of servings in the pan may be determined by
calculating the total weight and dividing it by a weight per
serving. By accessing recipe comparison tools (e.g., as may be
available via resources on the Internet) that may include lists of
corresponding meals that have lower fat, higher nutritional
ingredients, alternate recipes could be suggested to the user that
would provide comparable nutrition with lower calories or fat, for
example.
[2136] A food investigation application may gather information from
the smart cooktops and user activity about recipes being used by
users of the smart cooktop systems throughout a region (e.g., a
country such as India) to calculate various metrics, such as most
often cooked recipe, preferred breakfast meal, popular holiday
recipes, and the like. This information may be useful in planning
purposes by food suppliers, farmers, homeowners, and the like. As
an example, on any given day, information about the recipes that
people in your region are preparing might be useful in determining
which dishes are trending. An Internet-based server that receives
recipe and corresponding limited demographic information over time
may determine which meals are trending. A count of all uses of all
recipes (or comparable recipes) during a period of time (e.g.,
during evening meal preparation time) may be calculated and the
recipes with the greatest use counts could be identified as most
popular, currently trending, and the like.
[2137] Cooking becomes more repeatable so a cook (e.g., a less
experienced cook) may rely on the automation capabilities of an
Internet-connected smart cooktop system to avoid mistakes, like
overcooking, burning due to excessive heat, and the like. This may
be possible due to use of information about the items being cooked
and the cooking environment, such as the caloric output value of
each burner in any heat output setting, the weight of the food
being cooked, target temperature and cooking time (e.g., from a
recipe), a selected doneness of the food, and the like. By
combining this information with modeled and/or sensed burner
operation (e.g., temperature probes may be used to detect the
temperature of the food being cooked, the temperature of the
cooking environment, and the like) to facilitate automated control
of heat, temperature, and cooking time thereby making meal cooking
repeatable and predictable. Each type of burner (e.g., induction,
electric, LP gas, hydrogen gas, and the like) may each be fully
modeled for operational factors so that cooking a recipe with
induction heating today and with hydrogen gas heat tomorrow will
produce repeatable results. Similar capabilities to combine
information from the cooking system and information from sensors or
other systems may be used to improve repeatability and improvement
of industrial processes, such as manufacturing processes that
produce materials and components through heating, drying, curing,
and the like.
[2138] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with hydrogen production,
storage, and use systems. In embodiments, the hydrogen production,
storage, and use systems may use renewable energy as a source of
energy for various operations including hydrogen production,
hydrogen storage, distribution, monitoring, consumption and the
like. In embodiments, hydrogen production, such as with a
hydrolyzer system, may be powered by renewable energy such as solar
power (including systems using direct solar power and photovoltaic
systems (including ones using semiconductors, polymers, and other
forms of photovoltaic), hydro power (including wave motion, running
water, or stored potential energy), gravity (such as involving
stored potential energy), geothermal energy, energy derived from a
thermal gradient (such as a temperature gradient in a body of
water, such as ocean water, or a temperature gradient between a
level of the earth, such as the surface, and another level, such as
a subterranean area), wind power and the like and where applicable.
References to renewable energy throughout this disclosure should be
understood to encompass any of the above except where the context
indicates otherwise.
[2139] In embodiments, solar collector panels or the like may be
configured with a hydrogen production system, such as a system
described herein, to provide electricity for powering the
production of hydrogen, including from water. A hydrogen production
system may be built with integrated solar collector panels and the
ability to connect to further solar systems, so that placement of
the hydrogen production system in an ambient environment that is
exposed to sunlight may facilitate its self-powered operation or
partially-self-powered operation via solar power.
[2140] In embodiments, solar power harvesting subsystems, such as a
single panel or an array of solar panels, may be configured to be
deployed separately, and optionally remotely, from the hydrogen
production system. Solar power harvesting subsystems may be
connected to one or more hydrogen production systems to facilitate
deployment in environments with localized limited access to
sunlight, such as in a multi-unit dwelling, a building with few
windows, a building with interior areas that do not receive direct
or sufficient sunlight (such as a warehouse, manufacturing
facility, storage facility, laboratory, or the like) and the like.
Other operational processes of a system for hydrogen production,
storage, and use may be powered via solar power.
[2141] Solar energy harvested for the production of hydrogen may be
shared and/or diverted to these other operations or sold back into
the local grid as needed. Solar energy harvesting may also be used
to charge a battery, charge various thermal systems, or other
electrical energy storage facility that may directly provide the
energy needed for hydrogen production immediately or with a
time-shift and on-demand functions and other operational elements
as described herein. In this way, while solar power provides a
renewable source of energy, the impact of an absence of sunlight
and therefore diminished solar power production may be mitigated
through the use of an intermediate battery or the like.
[2142] In embodiments, a data collection system, involving one or
more sensors and instruments, may be used to monitor the solar
power system or components thereof, including to enable predictive
maintenance, to enable optimal operation (including based on
current and anticipated state information), and the like.
Monitoring, remote control, and autonomous control may be enabled
using machine learning and artificial intelligence, optionally
under human training or supervision, as with other embodiments
described herein. These capabilities for data collection,
monitoring, and control, including using machine learning, may be
used in connection with the other renewable energy systems, and
components thereof, described throughout this disclosure.
[2143] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with other sources of
renewable energy including wind power. Wind power may be harvested
through a windmill, turbine, roots-blade configuration, or similar
wind power collection facility that may be configured with the
hydrogen production, storage and use systems and components similar
to a solar collection facility or other electric sources as
described herein. In many examples, configuring a turbine or
similar wind power collection and conversion device attached to a
hydrogen production, storage, and use system may facilitate
deployment in a variety of environments where sufficient moving gas
(such as blowing wind, air flowing around a moving element (such as
part of a vehicle), exhaust from an industrial machine or process,
or the like) is available. These and other embodiments are intended
to be encompassed by the term "air flow" in this disclosure except
where the context indicates otherwise.
[2144] In embodiments, a variety of sources of air movement may be
utilized as a source of power from the air flow. In various
examples, heated air that may result from the use of the hydrogen,
such as for cooking and the like, may pass through a wind
harvesting facility, such as a turbine that may be disposed in the
heated air flow path. In embodiments, other heat harvesting devices
may be deployed such as positive displacement device or other
heated mediums through which energy may be absorbed and power a
suitable heat engine. In embodiments, disposing a turbine or other
energy/heat harvesting devices directly above a stove, cooking
system, or other heat generating use of the hydrogen produced may
produce energy that may be used to power, directly or indirectly,
partially or wholly, such as through recharging a battery,
operational processes of a hydrogen production, storage and use
system.
[2145] In yet another use of renewable energy for powering one or
more operational processes of a hydrogen production, storage,
and/or use system, such as may be described herein, hydropower may
be a source of renewable energy. In embodiments, hydropower may be
converted into a form that is usable to operate processes of a
hydrogen production, storage and use system as described herein
including electrical production and possibly harvesting mechanical
power. In these examples, electricity from hydropower may be
utilized to operate a hydrolyzer to produce hydrogen from a
hydrogen source, such as water or ambient air-based water vapor. In
embodiments, configuring a hydrogen production, storage, and use
system that may directly utilize hydro power may involve building
an enclosure that keeps a source of hydropower, such as a moving
body of water (e.g., a river, waterfall, water flowing through a
dam, and the like) from interfering with the operational processes
such as hydrogen production, storage, and use. In embodiments, such
an enclosure may facilitate deployment of a hydropower-sourced
system directly in a flow of water by making at least portions of
such a system submersible. Hydrogen production and storage, for
example, may benefit from such an enclosure. In particular, a
submersible hydrogen production system may take advantage of the
hydrodynamic water in which the system is submerged as a source of
hydrogen, as a source of energy to produce the hydrogen, as a
source to cool the process, or the like.
[2146] Referring to FIG. 282, embodiments of the methods and
systems related to renewable energy sources for hydrogen
production, storage, distribution and use are depicted. A system
the facilitates use of renewable energy as described herein may
include a hydrogen production facility 5074 that may be coupled to
a hydrogen storage facility 5703. The hydrogen production facility
5705 and/or the hydrogen storage facility 5703 may be coupled to
one or more hydrogen use facilities 5707. One or more of the
hydrogen use facilities 5707 may be coupled through a hydrogen
distribution network (not shown).
[2147] Hydrogen production, storage, distribution, and use may be
at least partially powered by one or more renewable energy sources,
such as solar energy source 5709, wind energy source 5711, hydro
energy source 5713, geothermal energy source 5715, and the like. A
wind energy source 5711 may be natural air currents, motor driven
air currents, air currents resulting from movement of a vehicle, or
waste air flow sources 5719 (such as waste heat from heating
operations, such as cooking and the like). Any of these renewable
energy sources may be converted into a form of energy that is
suitable for an intended use by the hydrogen production, storage,
distribution, and use system. As an example, a solar energy source
5709 may be converted to electricity as described herein to provide
electrical power to the hydrogen production facility 5705, hydrogen
storage facility 5703, use facility 5707 and the like. It will be
appreciated in light of the disclosure that the hydrogen storage
facility 5703 need not be required to operate with the hydrogen
production facility 5705 and the hydrogen use facility 5707 as the
produced hydrogen may be consumed upon its production without a
need for storage.
[2148] Another form of energy that may be sourced by the hydrogen
production facility 5705 may include a sulfur dioxide source 5717,
such as fossil fuel combustion systems that produce waste sulfur
dioxide. As described herein, a sulfur dioxide source 5717 may
supply heat energy and raw material from which hydrogen gas may be
produced by a hydrogen production facility 5705 adapted to use
sulfur dioxide.
[2149] Yet another form of energy that may be sourced by the
hydrogen production facility 5705 and/or storage facility 5703 may
include heat recapture 5721 from one or more of the hydrogen use
facilities 5705. The recovered heat may be used directly, converted
into another form, such as steam and/or electricity, or provided as
input raw material from which hydrogen may be harvested.
[2150] Referring to FIG. 283, an alternate embodiment of renewable
energy use with at least one hydrogen production facility 5705, at
least one hydrogen storage facility 5703. In the embodiment of FIG.
283, hydrogen production, storage, distribution, and uses may be
connected, but may not be integrated, such as into a standalone
combined function system. In the embodiment of FIG. 283, renewable
energy sources as described for the embodiment of FIG. 282 may be
used to provide energy for hydrogen production 5705 and storage
5703. However, hydrogen use may be provided through a hydrogen
distribution system 5823 that may be coupled to the hydrogen
production facility 5705, storage facility 5703 and to hydrogen use
facilities 5707 that may be located at distinct physical locations,
such as individual apartments in an apartment building, and the
like.
[2151] Referring to FIG. 284, the methods and systems described
herein for hydrogen production, storage, distribution, use, and
control may be coupled with predictive maintenance methods and
systems to facilitate improvements in operation with less unplanned
downtime and fewer component failures. In the embodiment of FIG.
284, predictive maintenance facility 5903 may be configured to
operate on a processor associated with or more particularly
integrated with a hydrogen production, storage, and use facility.
Alternatively, predictive maintenance facility may be configured to
operate on a processor that is not integrated, such as a cloud
computer, a stand alone computer, a networked server, and the like.
Predictive maintenance facility 5903 may receive input from various
system sensors 5905 along with information from various data sets,
such as a use/maintenance model 5915, warranty and standards rules
5919, and an archive of sensor data and analytics derived there
from 5917, among other sources.
[2152] System sensors 5905 may include hydrogen system sensors,
input energy sensors, process sensors (e.g., catalytic sensors and
the like), output sensors, use sensors, and a range of other
sensors as described herein. Each or any of these sensors may
provide data directly or through an intermediate processor a data
acquisition unit, a cross-linked data acquisition unit, and the
like to the predictive maintenance facility 5903. For a
local/integrated predictive maintenance facility 5903, sensor data
may be provided through a range of inputs, including direct inputs
and the like. For a remote/cloud preventive maintenance facility,
sensor data may be provided through a networking interface, such as
the Internet, an intranet, a wireless communication channel, and
the like.
[2153] The predictive maintenance facility 5903 may further be
coupled with a local or remote user interface for providing
reports, facilitating control, interacting with the predictive
maintenance facility 5903 to facilitate user participation in
maintenance actions, planning, and analysis. The user interface
facility 5909 may be integrated with the predictive maintenance
facility 5903, such as being an integrated component of a hydrogen
production, storage, and use system. Alternatively, the user
interface 5909 may be remotely accessible, such as through a
network, a cloud network facility, and the like including without
limitation the Internet and the like.
[2154] To facilitate at least semi-automated predictive
maintenance, replacement parts, service, and the like may be
automatically ordered based on a result of the predictive
maintenance facility 5903 indicating that some form of preventive
activity is required. The automatic part/service ordering facility
5913 may be connected directly or indirectly to the user
interface/control facility 5909 to enable users to approve or
adjust an automated order.
[2155] The embodiments of FIG. 284 include at least two
configurations; (i) an integrated hydrogen cooking/heating system
with predictive maintenance 5911, and (ii) modular system that may
take advantage of shared resources such as cloud computing
capabilities, cloud storage facilities and the like.
[2156] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with one or more computing
device functions that interface with operational, monitoring, and
other electronic aspects of a hydrogen production, storage and
optional use system as described herein and that may be accessed
through a variety of interfaces. Functions, several of which are
described elsewhere herein, may include control and monitoring of
hydrogen production, control, and monitoring of hydrogen storage
including distribution and the like, control and monitoring of the
use of generated and/or stored hydrogen. In embodiments, access to
these functions, such as to provide control input and receive
monitor output, may be done through an interface, such as an
application programming interface (API) or an interface to one or
more services, such as in a services oriented architecture, that
may expose certain aspects of these functions, services,
components, or the like, to facilitate access thereto. The terms
"API" or "application programming interface" should be understood
to encompass a variety of such interfaces to programs, services,
components, computing elements, and the like except where the
context indicates otherwise.
[2157] In embodiments, API type interfaces may include a library of
features, such as algorithms, software routines, and the like
through which the exposed aspects may be accessed. In embodiments,
API type interfaces may facilitate access to a control function of
a hydrogen production subsystem as described herein to enable
third-party control and/or monitoring of the subsystem, to
facilitate analytics with outside resources, to facilitate
interconnection of multiple resources, coordination of fuel and
renewables between multiple systems, and the like. In embodiments,
a single hydrogen production subsystem may be utilized to provide
hydrogen to a plurality of hydrogen storage systems. By way of
these examples, one or more of the hydrogen storage systems may use
the API or API-type interface to access a flow valve, fuel
distribution architecture, or the like that may facilitate
distribution of hydrogen produced by the storage systems so that
storage systems that are at or near storage capacity may direct a
control function of the flow valve to reduce or stop distribution
of the hydrogen to the storage system. In embodiments, Application
programming interfaces may be utilized across a range of control
and monitoring functions, including providing access to hydrogen
consumption monitoring elements, renewable energy utilization
monitoring systems, hydrogen use systems, smart cooktop systems as
described herein, and the like.
[2158] In addition to API type interfaces as described herein, a
hydrogen production, storage, and use system may be accessed
through one or more machine-to-machine interfaces. In embodiments,
such interfaces may include directly wired interfaces, such as
between a monitoring machine and a sensor disposed to sense the
flow of water, the flow of energy used for hydrolysis, the flow of
resulting hydrogen, or one or more levels, such as liquid levels,
of any of the foregoing. In embodiments, machine-to-machine
interfaces may be indirect, such as through a standard
communication portal such as network, e.g., an intranet, an
extranet, the Internet, and the like. In embodiments, communication
protocols such as HTTP and the like may be utilized to exchange
control, monitoring, and other information between some portion of
the hydrogen production, storage, and use system and another
machine. In embodiments, a machine-to-machine interface may
facilitate third party control of hydrogen use. This may manifest
itself in a variety of modes, examples of which may be a user
remotely accessing a cooking function from his mobile device using
the Internet as a machine-to-machine interface between the mobile
device and the cooking function.
[2159] In embodiments, interfacing with a hydrogen production,
storage and use system as described herein may also be accomplished
through a graphical user interface (GUI). In the many examples,
such an interface may facilitate human direct access to control,
monitoring, and other features of the system. In embodiments, a GUI
may include a variety of screens that may be logically related to
facilitating user access to a range of features of the system
within a single GUI. In the many examples, there may be a main
system GUI screen that may include links to a main production GUI
screen that may include, among other things, links to further
production GUI screens, e.g., a main screen may link to an energy
source control screen, a storage system control, system health,
predictive information, and the like. In embodiments, a main GUI
screen may also facilitate accessing one or more GUI screens for
other aspects of the system, such as hydrogen storage monitoring
and control, hydrogen distribution monitoring and control, hydrogen
use, cooking functions of a smart cooktop, heating functions for a
heater subsystem, and the like.
[2160] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with predictive maintenance
functions that may facilitate smart replacement of components
thereby avoiding failure and down time. In embodiments, predictive
maintenance functions that are described herein may be further
enhanced using one or more sensors that may facilitate monitoring
and/or control of portions of the system that may require
maintenance. In the examples, one or more sensors may be deployed
that facilitate monitoring and/or control of an electrolyzer
function. By way of the examples, the one or more sensors that may
monitor the membrane portion of the electrolyzer may provide data
that may be useful for detecting one or more conditions that
requires attention immediately or may culminate with other factors
and may later require attention, such as a condition that requires
the membrane to be replaced. Such sensors may further be configured
to generate one or more alerts, such as audio, visual, electronic,
logical signals when sensing a condition that may indicate
replacement of the membrane or other portion of the hydrolyzer is
recommended. Such sensors may further be configured to generate one
or more alerts that may trigger one or more recordings of data from
the sensors for a long duration to capture signals that may capture
events at various intervals, frequencies, and magnitudes that may
be indicative of the need to replace the membrane or other portion
of the hydrolyzer. Examples of the membrane and the electrolyzer
are disclosed in U.S. Pat. No. 8,057,646 to Hioatsu, et al, filed
on 7 Dec. 2005, and U.S. Pat. No. 6,554,978 to Vandenborre, filed 1
Jun. 2001, each of which is hereby incorporated by reference as if
fully set forth herein.
[2161] In embodiments, such alerts may be generated by the sensors
and/or by one or more computing facilities that may interface with
the sensors and may analyze data from the sensors. In embodiments,
sensors, such as a membrane sensor, may be integrated into the
system physically (to monitor a physical aspect of the system),
and/or logically (such as an algorithm that processes data from one
or more sensors). In embodiments, one or more membrane sensors, or
the like, may detect one or more conditions that may be indicative
that another action or precaution should be taken. In embodiments,
one or more alerts from such sensors may indicate the type of
condition sensed as well as a degree of the condition sensed. In
embodiments, when sensor alert and/or sensor data is combined with
other information known about the system, an alert may be generated
that indicates one or more actions or precautions that should be
taken to counteract the condition causing the alert. In one
example, an alert (or set of alerts) may require an action to
reduce an amount of hydrogen being produced, such as by turning off
or cycling with a greater duty cycle the operation of the
hydrolyzer.
[2162] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with sensors that may
monitor interconnections for corrosion or other conditions, such as
internal buildup that reduces the flow of hydrogen or the like
through the interconnections that may be associated with the
system. In embodiments, such sensors may provide data indicative of
a degree of corrosion, conditions that might speed corrosion, and
the like to a computing device that may detect a condition
indicative of needing to take action immediately or at such time as
the degree of corrosion would demand such as replace an affected
portion of the interconnections. In an example, the one or more
conditions may be determined by comparing data from the one or more
sensors with data values that suggest an unacceptable degree of
corrosion.
[2163] In embodiments, a monitoring subsystem with one or more
sensors may collect, analyze, and/or report the real-time
measurement of sensed data. Likewise, such a subsystem may collect,
analyze, and/or report real-time failure data, such as to
facilitate measuring and/or tracking material failure data, e.g.,
frequency, degree, time since deployment, and the like.
[2164] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with other sensing
modalities to monitor catalytic activities to determine, for
example, catalytic performance, efficiencies and the like. Based on
these sensed activities, alerts that may indicate a need for
catalyst replacement and/or other actions or precautions to be
performed may be generated.
[2165] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with various methods and
systems to monitor and determine input demand, output production,
need for increases therein, and the like.
[2166] In embodiments, a facility with multiple hydrogen operations
including production and/or storage may be shown to benefit from
monitoring to balance storage and production rate capacity, such as
for variable demand. In embodiments, monitoring input demand may
provide insight into the amount of hydrogen being used, when it is
used, with what other gases it is being used, which use subsystems
are demanding input, quality of hydrogen produced, amount of energy
required to produce the hydrogen, rate of hydrogen production and
use over time and under a variety of conditions, and the like. In
embodiments, sensors may be deployed and integrated with monitoring
and control systems to monitor and coordinate efficient and safe
storage or transfer of hydrogen.
[2167] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with one or more sensors to
monitor and coordinate efficient and safe storage and/or transfer
of hydrogen may be implemented in the Internet of things (IoT)
applications. In examples when hydrogen is stored as part of a
micro/smart grid solution, monitoring system functions, such as
input demand, production, and storage may facilitate determining a
need for increasing input/supply. Likewise, sources of energy for
operating a hydrolyzer and the like as described herein, such as
renewable energy from solar and wind may be managed so that
available sunlight and/or the wind may be tied to hydrogen
production demand predictions from users such as industrial and
others. In embodiments, this may facilitate ensuring allocation of
available hydrogen for grid stability and the like. In embodiments,
sensors that measure integrated energy use may similarly provide
information to further facilitate managing for grid stability,
among other things. In examples, predicted demand may be used in
determining when and how much hydrogen should be produced and
whether it should be stored to facilitate grid stability. In
embodiments, this information may be used when portions of a grid
are predicted to have high demand, while other portions are
predicted to have low demand. Supply, from the production of
hydrogen and/or from stored hydrogen, may be directed where when it
is predicted to be needed or it is predicted to be needed in
possibly relatively fewer quantities but may be consumed more
quickly.
[2168] In embodiments, another form of system sensing may involve
fuel quality sensing. In embodiments, sensors that may accurately
measure fuel and oxidant compositional characteristics may be used
in a control system to direct hydrogen to different storage
facilities based on the information. By way of these examples, uses
of hydrogen that may tolerate higher oxidant composition may be
sourced from storage facilities appropriately, perhaps at a lower
cost than for hydrogen with a lower oxidant composition.
[2169] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with sufficiently reliable
flame monitoring systems that may sense one or more of flame
quality, flame stability, flame temperature, and the like. In
embodiments, the methods and systems disclosed herein may include,
connect with or be integrated with one or more sensors that may
provide for continuous flue gas analysis that may be used to adjust
the efficiency and magnitude the flame. In embodiments, further
sensors and control systems related to flame or combustion products
monitoring may be used including one or more continuous heat flux
meters.
[2170] In embodiments, the methods and systems disclosed herein may
include, connect with or be integrated with one or more particle
sensors to determine how clean something is, e.g., exhaust and/or
ambient release from a process or liquid including from hydrocarbon
combustion. In embodiments, one or more emission detection sensors
may be used detect inefficient combustion and may also be used to
detect leaks from the system. By way of these examples, the one or
more sensors may be configured to measure partial pressure or
particle count when sensing internal and/or external emission such
as diatomic hydrogen, carbon dioxide, carbon monoxide, and other
combustion byproducts. The one or more sensors may be configured to
measure combustion wave front, cylinder head temperature,
lubrication cleanliness and/or entrainment, various vibration
signals that may be indicative improper operation.
[2171] In embodiments, methods and systems that may include,
connect with, or be integrated with hydrogen production, storage,
and use may be deployed in a variety of environments. Systems that
may facilitate production of a consumable energy source, such as
hydrogen gas may be utilized in environments such as cooking meals
or food preparation heating and/or cooking processes, including
without limitation industrial cooking.
[2172] Preparation of meals or of food items that may be stored
long term, such as canned foods and the like may be performed with
the methods and systems described herein. Preparation of meals or
food items in environments in which direct access to a reliable
source of energy, such as electricity, natural gas, or other
household combustibles for cooking or otherwise is not readily
available, such as in mobile, sea-borne, air-borne, and other
environments that are often actively in travel may be shown to
benefit from the methods and systems described herein for
autonomous production of hydrogen gas for use as a cooking energy
source. Use of a cooking system that is described herein may be
beneficial for use in mobile environments by reducing a total
amount of fuel to be stored for use while in motion. By producing a
clean burning energy source, such as hydrogen from renewable energy
sources and through harvesting hydrogen from an ambient
environment, deploying such systems on long duration travel
vehicles, such as cargo ships, military ships, submarines, and the
like may reduce the payload required to be carried for purposes
such as meal preparation, cooking and the like.
[2173] Renewable energy to power processes of hydrogen production,
monitoring, storage, distribution, and use may be harvested through
the methods and systems described herein including solar power
harvesting, wind power harvesting, thermal (e.g., geothermal) when
deployed in mobile environments. Solar energy harvesting systems or
components thereof that may be included with, connected to, or
integrated with the hydrogen production, storage and use systems
described herein may be deployed on sun-exposed surfaces, such as a
roof of a vehicle, aircraft, ship, and the like. Air movement
around and/or through a moving vehicle, as a result of propulsion
of the vehicle and the like may be harvested and converted into an
energy source suitable for use with hydrogen production, storage,
distribution and the like. Heat generated by mobile system
propulsion systems may be converted into a form of energy suitable
for use in production, storage, distribution, and use of hydrogen.
This may be accomplished through the use of inline turbine systems,
other heat and energy extraction machines, wind capture systems,
exhaust heat recapture systems, and the like. By using these
readily available sources of energy, many of which are not
otherwise utilized, total external energy requirements that may
only be met through onboard storage, may be significantly
reduced.
[2174] Use of the methods and systems for hydrogen storage and use
may include deployment in marine transportation, such as on a
submarine where the generation of toxic waste gas is undesirable.
Hydrogen gas may be produced from sea water, stored as needed
onboard, and safely consumed for cooking and other heating uses in
a submarine without risk or costs of dealing with waste gas
cleansing or removal. The hydrogen gas may be produced from sea
water but not stored any only generated and consumed as needed
onboard, and safely consumed for cooking and other heating uses in
a submarine.
[2175] Other environments of deployment of the hydrogen-based
systems described herein may include use on aircraft, such as for
preparation of meals to be consumed on the flight. Other
aircraft-based uses may include industrial cooking while in-flight
to, for example, produce cooked goods for use, storage or
distribution after the aircraft returns to earth. Inflight-based
cooking with the methods and systems for autonomous hydrogen
cooking systems and the like described herein may facilitate
cooking food and the like for extended duration flights, such as
aircraft that remains aloft rather than just being operated from
one location to another. Meals, foods, and other goods could be
cooked while in-flight may be transported to/from the in-flight
aircraft through shuttle or other aircraft to facilitate longer
duration flights.
[2176] Earth-bound operations such as drilling and mining that may
have very limited access to cooking fuel or other commercially
available fuel sources may be shown to benefit from the use of such
a system. Equipment that transports materials, supplies, and
workers to/from subterranean drill sites and mines may be equipped
with such a system to facilitate preparation of food for the
workers. Use of a fuel, such as hydrogen that produces no toxic
exhaust may be well suited for use in drilling and mining
environments.
[2177] Agricultural production, including harvesting, planting, and
the like may also benefit from the deployment of hydrogen-based
cooking and/or heating systems as described herein. Food
preparation operations that may include heating or cooking freshly
harvested foods may be shown to benefit from an automated or
semi-automated hydrogen-based cooking system as described herein.
Such a system may be deployed on or connected with a harvesting
system, such as a produce harvester and the like so that cooking,
preserving, sterilizing, pasteurizing, drying or optional storage
operations may occur as the food is harvested. Other deployments,
such as industrial cooking deployments, may include job-site
deployment, food truck deployment, canteen truck deployment, food
production pipelines, and the like. Yet other deployments, such as
industrial cooking deployment may include residential environments,
such as nursing homes, group homes, soup kitchens, school and
business cafeterias, disaster relief food preparation stations, and
the like.
[2178] The methods and systems of autonomous or semi-autonomous
hydrogen production, storage, distribution, and use may be deployed
as components in a smart power grid that may operate cooperatively
with other components of a smart grid to attempt to deliver
reliable energy available throughout the grid. In an example, a
renewable energy-based hydrogen production system may utilize its
renewable energy harvesting components to deliver electricity to a
smart grid based on various factors, such as local demand for
hydrogen and the like. When a renewable energy source is available,
yet hydrogen production is not called for (e.g., sufficient supply
is stored, or an amount that is anticipated to be needed, such as
based on machine learning or the like of prior local hydrogen
demand over time is expected to be producible before needed), then
electricity or the like produced from the renewable energy source
could be fed back into the smart grid.
[2179] Other types of industrial applications of the methods and
systems of hydrogen production, storage, distribution and use may
include air and inline heaters, and the like. Exemplary
environments may include deployment for aerospace operation and
testing, such as component temperature testing, heating, hot air
curing, and the like. Production of temperatures that emulate
extremes associated with aerospace travel, such as earth atmosphere
entry and the like could be replicated with such systems for use in
component testing and the like.
[2180] Other industrial heating applications may include automotive
production (e.g., heat treating components, heat shrinking and the
like), automotive assembly (e.g., hot air bonding, etc.),
automotive exterior and interior customization (e.g., hot air
bonding of vinyl body panel covers, paint curing and the like), and
automotive repair (e.g., reshaping dented plastic components, such
as a bumper) and the like.
[2181] Yet other industrial heating applications may include
packaging, sterilization, and the like. Particular packaging uses
may include high-speed poly-coated paperboard sealing, high-speed
heat shrink installations, material heat forming, curing adhesives,
sterilizing bottles and cartons (e.g., through heating water and/or
steam therefore), production and packaging of pharmaceuticals,
sterilization and packaging of surgical tools and hardware,
replacement dental features (e.g., crowns and the like), production
and sealing of packaging material, and the like.
[2182] Paper and printing heating-related applications of the
methods and systems described herein may include the production of
coated paper, including speed drawing the coating, adhesive
activation, ink drying, paper aging, pulp drying, and the like.
[2183] Plastics and rubber production heating applications that may
be shown to benefit from the methods and systems described herein
may include rubber extrusion salt removal, curing plastics, bending
and forming plastic components, de-flashing of molded parts and the
like.
[2184] The methods and systems described herein may be used to
produce heat needed for some semiconductor and electronics
production and assembly operations including soldering operations,
such as air knife for wave soldering, heating of printed circuit
boards, lead frames, components (e.g., capacitors) for
soldering/desoldering, centralized source of heat for a
multi-station desoldering system, wafer and PC board drying, heat
shrink wire insulation, preheating process gases and the like. By
way of these examples, soldering and/or brazing may require heating
that may be provided by the hydrogen-based heating systems
described herein. Heat for soldering and brazing may be generated
locally at each brazing station or may be provided from a
centralized source for multiple soldering operations, including
manual and semi-manual operations.
[2185] Other heated air applications that may be suitable for
application of a hydrogen-based system as described herein may
include textiles industrial uses, such as welding plastic or vinyl
fabrics, heat-treating specialty fabrics, heat sealing fabric
shipping sleeves, bonding multi-ply fabrics and the like.
Industrial hot air applications may include the exemplary
embodiments described herein, but may also include other comparable
applications, such as home fabric bonding, plastic sheet dispensing
and the like in which heat is used to increase the temperature of
air or devices to perform various functions.
[2186] In embodiments, the methods and systems described herein
that relate to hydrogen production, storage, distribution, use,
regulation, monitoring, control, energy conversion, and the like
may also be used for heating operations including immersion,
circulation and customer heating. Example applications include
energy production environments where fuel sources for cooking and
heating may be used, such as alternative fuels processing, chemical
processing, mining and metals, oil, and gas, petrochemical, power
generation, fuel storage, fuel distribution, heat exchangers, waste
disposal, heated storage, and the like. Industrial applications may
include biopharmaceutical processing, industrial equipment (such as
temperature test chambers), engine block heaters, preheating
industrial burners, furnaces, kilns and the like, medical equipment
laboratory and analytic equipment, military and defense including
weapons, personnel management, and other military uses, production
of rubber and plastics through controlled heating of petrochemicals
and the like, transportation (such as passenger compartment
temperature regulation, preheat or temperature regulation of
vehicle systems in extremely low temperature environments) and the
like, water processing, waste water processing and the like.
Commercial applications of the methods and systems described herein
for use as heating for immersion, circulation and the like may
include integration, connection or use with commercial food
equipment, building and construction systems, commercial marine and
shipping systems and environments, heat-powered cooling,
refrigeration, air conditioning, and other cooling applications and
the like.
[2187] In addition to cooking and air heating applications, the
methods and systems of autonomous hydrolyzer operation, generated
fuel storage, distribution and use described herein may also be
applied to processes that use heat from a heating element that may
be powered from the fuel (e.g., hydrogen and the like) produced
from the hydrolyzer. Manufacturing operations may include
pharmaceutical manufacturing, industrial food manufacturing,
semiconductor manufacturing, and the like. Other heating
element-like applications may include coating such as vinyl
automotive panel wrapping, molding such as injection molding, heat
staking, and the like, hard tooling, heating material for extrusion
operations, combustion systems (such as flame-based combustion
devices, e.g., burners that would improve on existing combustion
methods including improving efficiency, cost, reduce or eliminate
emissions), enhance heat transfer from combustion products to the
material processed for a variety of applications, such as by
applying a clean-burning fuel in proximity to the material being
processed, other types of combustion systems (e.g., non-burner
types) such as catalytic combustion, combustion systems that
include heat recovery devices such as self-recuperative burners,
and the like.
[2188] Other applications for heat-dependent operations that may be
powered by the fuel produced from a hydrolyzer may include heat and
power uses such as integrated heating systems such as super boilers
and other applications that deliver both heat and power to an
operation (e.g., super pressurized steam systems, and the like).
Other heat utilization applications may include heat production
include use for testing materials such as products for mining
(e.g., heat treating drilling machine elements), drying and
moisture removal (such as clothes dryers, dehumidifiers, and the
like). Other applications in which a hydrolyzer-based energy
producing system may be used include heat as a catalyst for
chemical reactions and processing including, without limitation
chemical scrubbing of exhaust from industrial systems including
petrochemical-based combustion systems, on-site production of
chemicals, such as high-value petroleum products from lower grade,
lower cost petroleum supplies, and the like.
[2189] Other applications that may benefit from the use of an
autonomous hydrogen generation system as described herein may
include desalination, such as local desalination systems for
pleasure boats, ferries, and the like. Because of the high
efficiency and potential for only using renewable energy sources,
hydrogen generation-based desalination systems may be fully
self-operative, producing hydrogen directly from a source of water
being desalinated.
[2190] Yet other applications include using heat to power carbon
capture, purification of material and systems such as a palladium
electrolyzer, and the like. Industrial washing systems, such as
laundry, preheating boiler water feeds, sterilizing, sanitation,
and cleaning processes for clothing, uniforms, safety gear,
hospital and medical care facilities (e.g., floors and the like)
may also be target applications for systems that include, connect
to, or integrate hydrogen production, storage, and distribution,
including systems that are powered by renewable energy sources and
the like.
[2191] Filtering and purifying materials and equipment used in
various processes, such as food service, food manufacturing,
pharmaceutical production and handling, livestock handling and
processing and the like are also candidate application environments
for the methods and systems described herein. In production
environments that may rely on highly purified materials, such a
system may be applied to provide the necessary heating or energy
required. In embodiments, the methods and systems described herein
may be applied to corrosion and hydrogen embrittlement
activities.
[2192] Referring to FIG. 285 environments and manufacturing uses of
hydrogen production, storage, distribution, and use systems are
depicted. As described above herein, hydrogen system 5701 may be
deployed in environments including industrial cooking 6006,
industrial air heaters and inline heaters 6009, and industrial
environments 6011. A hydrogen system 5701 may also be used in
manufacturing use cases 6005, such as heat used in manufacturing
processes 6013. Deployment in environments 6003 and manufacturing
uses 6005 may overlap, resulting in a hydrogen system 5701
operating in combinations of environment and use that are depicted
in FIG. 285 and described herein.
[2193] The methods and systems described herein may be used to
provide hydrogen directly from a hydrolyzer for certain uses
including uses that do not require the introduction of oxygen. In
such embodiments that may only require a hydrogen gas, the hydrogen
may be produced and sent directly for real-time uses such as a
burner for heating, industrial heating processes like welding and
brazing, and all other use cases that require direct-use hydrogen.
Some other cases may include coating, tooling, extrusion, drying
and the like. The methods and systems described herein may produce
high-quality hydrogen gas for applications that require it, such as
laser cutting. Other uses may include the production of hydrogen
gas that may then be combined with other combustible gases for
operations such as to generate a flame suitable for welding, for
supplying an oxyhydrogen torch, and the like.
[2194] In applications where both the separated hydrogen and
separated oxygen may be required for different purposes, the
generation, storage, distribution and/or heating (e.g., cooking)
system may direct independently both gases to their appropriate
process uses. An example could be an electrolyzer on a submarine
where the hydrogen may be used for a burner, and the oxygen used in
the submarines air circulation system, and the like. In yet other
embodiments the oxygen and hydrogen that have been separated during
the hydrolysis process may need to be recombined under a protocol
that produces a desired combination and rate of the combination of
oxygen and hydrogen. One such example is Oxy-Hydrogen welding.
[2195] In embodiments, other examples of time-shifted uses of
electrolyzer products that may benefit from and/or include hydrogen
storage may include storing hydrogen in its non-compressed state,
in its gaseous state, in its compressed liquid state or
combinations thereof in a small tank that is part of a cooking or
other industrial system, in a larger tank on or near the cooking
system, or transported to very large holding tanks at a facility
that is not nearby. Further examples of hydrogen storage technology
may include absorbing the hydrogen by a substrate. The substrate
may then be stored in a small tank or other substrate storage
facility that may be part of the cooking system, in a larger tank
on or near the cooking system, transported to very large holding
tanks at a facility that is not nearby, or distributed across a
plurality of small, medium, and large storage facilities that may
facilitate local access to the stored energy. At the appropriate
time, the substrate may be heated and the hydrogen may return to
its original gaseous state.
[2196] Cooking and other heating systems that may use hydrogen as
one of a plurality of sources of fuel may participate in
automatically selecting among the sources of fuel. These systems
may include processing capabilities that are connected to various
information sources that may provide data regarding factors that
may be beneficial to consider when determining which energy source
to select. Determining which energy source to select may be based,
for example on a single factor, such as a current price for one or
more of the sources of energy. An energy source that provides
sufficient energy at a lowest current price may be selected. In
embodiments, a cooking or other heating system may automatically,
under computer control, be configured for the selected source of
energy. In an example, if hydrogen is selected, connections to a
source of hydrogen may be activated, while connections to other
sources may be deactivated. Likewise, burners, heater controls,
heat and safety profiles, cooking times, and a range of other
factors may be automatically adjusted based on the selected energy
source. If during a cooking or heating operation, another source of
energy is found to be less costly (such as electricity), systems
may automatically be reconfigured for use of the other source of
energy. Gas-fired heaters may be disabled and electric heating
elements may be energized to continue the cooking and/or heating
operation with minimal interruption. Such hybrid energy source
cooking and/or heating processes may require a distinct protocol
for completing a cooking or heating process based on the new source
of energy.
[2197] Alternatively, automatic selection of a fuel source may be
based on a multitude of factors. These factors may be applied to a
fuel source selection algorithm that may process individually, in
groups, or in combination a portion of the factors. Example factors
may include the price of other energy sources, including energy
sources that are available to the cooking and heating system as
well as those that are not directly available. In this way,
selecting an energy source may be driven by other considerations,
such as which energy source is better for the environment, and the
like. In embodiments, an automatic energy source selection may be
based, at least in part on the anticipated availability of an
energy source. In embodiments, predictions of energy outage, such
as brownouts, may be based on a range of factors, including direct
knowledge of scheduled brownouts and the like. Such predictions may
also be based on prior experience regarding the availability of the
source(s) of energy, which may be applied to machine learning
algorithms that may provide predictions of future energy
availability. Yet other factors that may be applied to an algorithm
for automatically determining a source of energy may include
availability of a source of water for producing hydrogen,
availability of renewable energy (e.g., based on a forecast for
sunlight, winds, and the like), level and/or intensity of need of
the energy, anticipate level of need over a future period of time,
such as the next 24 hours and the like. If an anticipate need over
a future period of time includes large swings in demand over that
timeframe, each peak in demand may be individually analyzed.
Alternatively, an average or other derivatives of the demand over
time may be used to determine a weighting for the various sources
of energy.
[2198] In addition to energy selection for direct application to
cooking and heating, energy selection for operating a hydrolyzer to
produce hydrogen may be automated. Energy sources that may be
included in such an automated selection process may include solar
energy, wind energy, hydrogen energy, sulfur dioxide, electricity
(such as from an electricity grid), natural gas, and the like. In
embodiments, an algorithm that may facilitate automatic energy
selection may receive information about each energy source, such as
availability, costs, efficiency, and the like that may be processed
by, for example comparing the information to determine which energy
source provides the best fit for operating the hydrolyzer in a
given time period. By way of this example, the algorithm may favor
energy sources that are more reliable, more available, and lower
costs than those that are less reliable, less available, and
costlier. In embodiments, combinations of these three factors may
result in certain sources being selected. If a demand for reliable
energy at a particular time is weighted more highly than price, for
example, a costlier energy source may be automatically selected due
to it being more reliably available. An automatic fuel selection
algorithm may also produce recommendations for fuel selection and a
human or other automated process may make a selection. In an
example, an automated fuel selection algorithm may recommend a fuel
that is less costly, but may be somewhat less reliable than another
source; however given the weighting or other aspects of the
available information about the sources, such a recommendation may
meet acceptance criteria of the algorithm.
[2199] Methods and systems described herein may be associated with
methods and systems for automatic selection of an energy source,
such as a method for determining an optimal use of renewable energy
(such as solar, wind, geothermal, hydro and the like) or
non-renewable fuel. In embodiments, a selection of energy source to
power an onsite, stand alone cooking or heating system may be based
on a variety of factors including access and distance to a source
of renewable energy source as a primary source, directly to the
cooking system. As an example, while production cost data available
regarding hydro-based renewable energy may support its selection, a
delivery network may not be in place or may charge a substantive
premium for access to that particular renewable source; therefore
hydro-based renewable energy may not be an optimal use.
[2200] In embodiments, other factors include pricing and amount of
electricity required to use the cooking system and electrolyzer and
the; ability of the source to match up availability with demand for
generated power is required for both sustained periods of usage as
well as short-term requirements. In embodiments, other factors that
may impact an automated energy source selection process may include
availability and ability to reuse excess heat from the cooking
system and/or other nearby industrial facilities. In embodiments,
excess heat may include exhaust heat, sulfur dioxide byproduct and
the like that may be used to generate heat through a heat exchange
process. In embodiments, another set of criteria for determining
which energy source may be optimal for use by a cooking system as
described herein may include comparing the need for short-term
accessibility to power at arbitrary times throughout the day,
compared to limiting timing of demand to power given timing and
availability of power sources, such as nearby power sources. Sulfur
dioxide as a waste heat byproduct may be used in a heat transfer
process to recapture heat from the sulfur dioxide gas; however, it
may also be applied directly to the hydrolyzer system to produce
hydrogen. In embodiments, the sulfur dioxide gas may be applied
directly to the hydrolyzer system to produce hydrogen and reduce
the sulfur dioxide gas as a tool for environmental abatement by
reducing the amount of the sulfur dioxide gas and use the generated
hydrogen to burn trash and other items for its removal, for
electricity generation, and the like.
[2201] In embodiments, external systems, such as information
systems may be associated with or connected to hydrogen production,
storage, distribution, and use systems as described herein.
Information systems may receive information from all aspects and
system processes including, energy selection (such as automated
energy selection) including actual results as compared to predicted
results, energy consumption, hydrogen generation for each type of
energy source (solar, hydro-based, wind, exhaust gas, including
sulfur dioxide use, and the like), hydrogen refinement processes,
hydrogen storage (including compressed, natural state storage,
substrate infusion-based, and the like), hydrogen distribution,
uses, combinations with other fuel sources (such as hydrogen with
another flammable energy medium) and the like, uses of the hydrogen
including timing, costs, application environment, and the like.
[2202] In embodiments, communication to and from external systems
may be through exchange of messages that may facilitate remote
monitoring, remote control and the like. By way of this example,
messages may include information about a source of the message, a
destination, an objective (e.g., control, monitoring, and the
like), recommended actions to take, alternate actions to take,
actions to avoid, and the like.
[2203] In embodiments, methods and systems related to hydrogen
production, storage, distribution and use may include, be
associated with, or integrate improvement features that may provide
ongoing improvements in system performance, quality and the like.
In embodiments, improvement features may include process control
and heat recovery, flow control and precision control, safety,
reliability and greater service availability, process and output
quality including output consistency. Other features that may be
provided and/or be integrated with the hydrogen-based systems
described herein may include data collection, analysis, and
modeling for improvement, data security, cyber security, network
security to avoid external attacks on control systems and the like,
monitoring and analysis to facilitate preventive maintenance and
repair.
[2204] In embodiments, integration and/or access to data processing
systems that also have access to third-party data may be included
in the methods and systems described herein. By monitoring data
collected from sensors, time of day, weather conditions, and other
data sources may be used with specific rule sets to trigger
activation and/or stoppage of hydrogen use (e.g., cooking)
operations. In embodiments, data may be accumulated in a continuous
feedback loop that may capture data for a range of metrics
associated with operations, such as cooking operations and the
like. In embodiments, analysis and control of activation of such a
system may factor in the actual requirements and timing when a
cooking system needs to be used (such as when a meal is being
prepared, such as breakfast, or when heating is required for an
industrial operation, such as at the start of a new work shift and
the like.
[2205] In embodiments, data collection, monitoring, process
improvement, quality improvement, and the like may also be
performed during operation of such a system. In an example, once a
cooking system is activated, the system may be able to determine
the best way to receive the heat required to perform the process at
hand at that particular moment in time. Receiving the heat required
to perform the process may be selected from a variety of heat
sources including in-line hydrogen production, stored hydrogen
consumption, combined energy utilization and the like. In
embodiments, cooking elements with a mix of hydrogen and
non-hydrogen heat burners may be automatically controllable so that
the system should be able to automatically, using machine learning
for example and continuous monitoring, decide to use one or the
other source or a combination thereof.
[2206] Further in this example, a smart cooktop may include burners
for hydrogen and for liquid propane. In embodiments, methods and
systems for cooking operation may automatically activate the
appropriate burner based on fuel selection (e.g., hydrogen burner
or the liquid propane burner.). Operating such a cooking or heating
system may be done by a computer enabled controller that may
process factors including time of day, spot-pricing energy costs
for each alternative, length of process involved, meeting 100%
green requirements, potential hazardous use of flame depending on
location of cooking system, other security features, and the like.
To faciliate continuous improvement during operational control,
data analysis may be performed on any or all aspects of the system.
In an example, if the electrolyzer is not activated, sensors may
capture information about the liquid propane burner that is being
used. In embodiments, this single data capture example indicates
that while it is desirable to collect information about all
operational aspects to avoid missing information, practical
considerations enable more focused data collection and analysis. In
embodiments, every activity and action by the cooking system and
heating element may be captured, recorded, measured, and used to
inform actions such as quality improvement and the like.
[2207] In embodiments, information may be provided for one or more
deployments of this cooking system to facilitate self-improvement
and real-time decision making. In embodiments, information captured
may also be stored and used in time-series analysis and the like to
determine patterns that may indicate opportunities for improvement.
In embodiments, data captured for a plurality of deployments may be
used for creating and updating models that may be used for
computer-generated simulations and the like. These models may be
applied to design processes and the like. In embodiments,
continuous improvement modifications may be activated by
machine-to-machine learning programs, human improvement efforts,
instructional improvement and/or modifications, and the like.
[2208] While the foregoing written description enables one skilled
in the art to make and use what is considered presently to be the
best mode thereof, those skilled in the art will understand and
appreciate the existence of variations, combinations, and
equivalents of the specific embodiment, method, and examples
herein. The disclosure should therefore not be limited by the above
described embodiment, method, and examples, but by all embodiments
and methods within the scope and spirit of the disclosure.
[2209] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software,
program codes, and/or instructions on a processor. The present
disclosure may be implemented as a method on the machine, as a
system or apparatus as part of or in relation to the machine, or as
a computer program product embodied in a computer readable medium
executing on one or more of the machines. In embodiments, the
processor may be part of a server, cloud server, client, network
infrastructure, mobile computing platform, stationary computing
platform, or other computing platform. A processor may be any kind
of computational or processing device capable of executing program
instructions, codes, binary instructions, and the like. The
processor may be or may include a signal processor, digital
processor, embedded processor, microprocessor, or any variant such
as a co-processor (math co-processor, graphic co-processor,
communication co-processor, and the like) and the like that may
directly or indirectly facilitate execution of program code or
program instructions stored thereon. In addition, the processor may
enable execution of multiple programs, threads, and codes. The
threads may be executed simultaneously to enhance the performance
of the processor and to facilitate simultaneous operations of the
application. By way of implementation, methods, program codes,
program instructions, and the like described herein may be
implemented in one or more thread. The thread may spawn other
threads that may have assigned priorities associated with them; the
processor may execute these threads based on priority or any other
order based on instructions provided in the program code. The
processor, or any machine utilizing one, may include non-transitory
memory that stores methods, codes, instructions, and programs as
described herein and elsewhere. The processor may access a
non-transitory storage medium through an interface that may store
methods, codes, and instructions as described herein and elsewhere.
The storage medium associated with the processor for storing
methods, programs, codes, program instructions, or other type of
instructions capable of being executed by the computing or
processing device may include but may not be limited to one or more
of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache,
and the like.
[2210] A processor may include one or more cores that may enhance
speed and performance of a multiprocessor. In embodiments, the
process may be a dual core processor, quad core processors, other
chip-level multiprocessor and the like that combine two or more
independent cores (called a die).
[2211] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software
on a server, client, firewall, gateway, hub, router, or other such
computer and/or networking hardware. The software program may be
associated with a server that may include a file server, print
server, domain server, internet server, intranet server, cloud
server, and other variants such as secondary server, host server,
distributed server, and the like. The server may include one or
more of memories, processors, computer readable transitory and/or
non-transitory media, storage media, ports (physical and virtual),
communication devices, and interfaces capable of accessing other
servers, clients, machines, and devices through a wired or a
wireless medium, and the like. The methods, programs, or codes as
described herein and elsewhere may be executed by the server. In
addition, other devices required for execution of methods as
described in this application may be considered as a part of the
infrastructure associated with the server.
[2212] The server may provide an interface to other devices
including, without limitation, clients, other servers, printers,
database servers, print servers, file servers, communication
servers, distributed servers, social networks, and the like.
Additionally, this coupling and/or connection may facilitate remote
execution of program across the network. The networking of some or
all of these devices may facilitate parallel processing of a
program or method at one or more locations without deviating from
the scope of the disclosure. In addition, any of the devices
attached to the server through an interface may include at least
one storage medium capable of storing methods, programs, code,
and/or instructions. A central repository may provide program
instructions to be executed on different devices. In this
implementation, the remote repository may act as a storage medium
for program code, instructions, and programs.
[2213] The software program may be associated with a client that
may include a file client, print client, domain client, internet
client, intranet client, and other variants such as secondary
client, host client, distributed client, and the like. The client
may include one or more of memories, processors, computer readable
transitory and/or non-transitory media, storage media, ports
(physical and virtual), communication devices, and interfaces
capable of accessing other clients, servers, machines, and devices
through a wired or a wireless medium, and the like. The methods,
programs, or codes as described herein and elsewhere may be
executed by the client. In addition, other devices required for
execution of methods as described in this application may be
considered as a part of the infrastructure associated with the
client.
[2214] The client may provide an interface to other devices
including, without limitation, servers, other clients, printers,
database servers, print servers, file servers, communication
servers, distributed servers, and the like. Additionally, this
coupling and/or connection may facilitate remote execution of a
program across the network. The networking of some or all of these
devices may facilitate parallel processing of a program or method
at one or more location without deviating from the scope of the
disclosure. In addition, any of the devices attached to the client
through an interface may include at least one storage medium
capable of storing methods, programs, applications, code, and/or
instructions. A central repository may provide program instructions
to be executed on different devices. In this implementation, the
remote repository may act as a storage medium for program code,
instructions, and programs.
[2215] In embodiments, one or more of the controllers, circuits,
systems, data collectors, storage systems, network elements,
components, or the like as described throughout this disclosure may
be embodied in or on an integrated circuit, such as an analog,
digital, or mixed signal circuit, such as a microprocessor, a
programmable logic controller, an application-specific integrated
circuit, a field programmable gate array, or other circuit, such as
embodied on one or more chips disposed on one or more circuit
boards, such as to provide in hardware (with potentially
accelerated speed, energy performance, input-output performance, or
the like) one or more of the functions described herein. This may
include setting up circuits with up to billions of logic gates,
flip-flops, multiplexers, and other circuits in a small space,
facilitating high speed processing, low power dissipation, and
reduced manufacturing cost compared with board-level integration.
In embodiments, a digital IC, typically a microprocessor, digital
signal processor, microcontroller, or the like may use Boolean
algebra to process digital signals to embody complex logic, such as
involved in the circuits, controllers, and other systems described
herein. In embodiments, a data collector, an expert system, a
storage system, or the like may be embodied as a digital integrated
circuit ("IC"), such as a logic IC, memory chip, interface IC
(e.g., a level shifter, a serializer, a deserializer, and the
like), a power management IC and/or a programmable device; an
analog integrated circuit, such as a linear IC, RF IC, or the like,
or a mixed signal IC, such as a data acquisition IC (including A/D
converters, D/A converter, digital potentiometers) and/or a
clock/timing IC.
[2216] The methods and systems described herein may be deployed in
part or in whole through network infrastructures. The network
infrastructure may include elements such as computing devices,
servers, routers, hubs, firewalls, clients, personal computers,
communication devices, routing devices and other active and passive
devices, modules and/or components as known in the art. The
computing and/or non-computing device(s) associated with the
network infrastructure may include, apart from other components, a
storage medium such as flash memory, buffer, stack, RAM, ROM, and
the like. The processes, methods, program codes, instructions
described herein and elsewhere may be executed by one or more of
the network infrastructural elements. The methods and systems
described herein may be configured for use with any kind of
private, community, or hybrid cloud computing network or cloud
computing environment, including those which involve features of
software as a service ("SaaS"), platform as a service ("PaaS"),
and/or infrastructure as a service ("IaaS").
[2217] The methods, program codes, and instructions described
herein and elsewhere may be implemented on a cellular network
having multiple cells. The cellular network may either be frequency
division multiple access ("FDMA") network or code division multiple
access ("CDMA") network. The cellular network may include mobile
devices, cell sites, base stations, repeaters, antennas, towers,
and the like. The cell network may be a GSM, GPRS, 3G, EVDO, mesh,
or other networks types.
[2218] The methods, program codes, and instructions described
herein and elsewhere may be implemented on or through mobile
devices. The mobile devices may include navigation devices, cell
phones, mobile phones, mobile personal digital assistants, laptops,
palmtops, netbooks, pagers, electronic books readers, music players
and the like. These devices may include, apart from other
components, a storage medium such as a flash memory, buffer, RAM,
ROM and one or more computing devices. The computing devices
associated with mobile devices may be enabled to execute program
codes, methods, and instructions stored thereon. Alternatively, the
mobile devices may be configured to execute instructions in
collaboration with other devices. The mobile devices may
communicate with base stations interfaced with servers and
configured to execute program codes. The mobile devices may
communicate on a peer-to-peer network, mesh network, or other
communications network. The program code may be stored on the
storage medium associated with the server and executed by a
computing device embedded within the server. The base station may
include a computing device and a storage medium. The storage device
may store program codes and instructions executed by the computing
devices associated with the base station.
[2219] The computer software, program codes, and/or instructions
may be stored and/or accessed on machine readable transitory and/or
non-transitory media that may include: computer components,
devices, and recording media that retain digital data used for
computing for some interval of time; semiconductor storage known as
random access memory ("RAM"); mass storage typically for more
permanent storage, such as optical discs, forms of magnetic storage
like hard disks, tapes, drums, cards and other types; processor
registers, cache memory, volatile memory, non-volatile memory;
optical storage such as CD, DVD; removable media such as flash
memory (e.g., USB sticks or keys), floppy disks, magnetic tape,
paper tape, punch cards, standalone RAM disks, zip drives,
removable mass storage, off-line, and the like; other computer
memory such as dynamic memory, static memory, read/write storage,
mutable storage, read only, random access, sequential access,
location addressable, file addressable, content addressable,
network attached storage, storage area network, bar codes, magnetic
ink, and the like.
[2220] The methods and systems described herein may transform
physical and/or or intangible items from one state to another. The
methods and systems described herein may also transform data
representing physical and/or intangible items from one state to
another.
[2221] The elements described and depicted herein, including in
flow charts and block diagrams throughout the Figures, imply
logical boundaries between the elements. However, according to
software or hardware engineering practices, the depicted elements
and the functions thereof may be implemented on machines through
computer executable transitory and/or non-transitory media having a
processor capable of executing program instructions stored thereon
as a monolithic software structure, as standalone software modules,
or as modules that employ external routines, code, services, and so
forth, or any combination of these, and all such implementations
may be within the scope of the present disclosure. Examples of such
machines may include, but may not be limited to, personal digital
assistants, laptops, personal computers, mobile phones, other
handheld computing devices, medical equipment, wired or wireless
communication devices, transducers, chips, calculators, satellites,
tablet PCs, electronic books, gadgets, electronic devices, devices
having artificial intelligence, computing devices, networking
equipment, servers, routers, and the like. Furthermore, the
elements depicted in the flow chart and block diagrams or any other
logical component may be implemented on a machine capable of
executing program instructions. Thus, while the foregoing drawings
and descriptions set forth functional aspects of the disclosed
systems, no particular arrangement of software for implementing
these functional aspects should be inferred from these descriptions
unless explicitly stated or otherwise clear from the context.
Similarly, it will be appreciated that the various steps identified
and described above may be varied, and that the order of steps may
be adapted to particular applications of the techniques disclosed
herein. All such variations and modifications are intended to fall
within the scope of this disclosure. As such, the depiction and/or
description of an order for various steps should not be understood
to require a particular order of execution for those steps, unless
required by a particular application, or explicitly stated or
otherwise clear from the context.
[2222] The methods and/or processes described above, and steps
associated therewith, may be realized in hardware, software or any
combination of hardware and software suitable for a particular
application. The hardware may include a general-purpose computer
and/or dedicated computing device or specific computing device or
particular aspect or component of a specific computing device. The
processes may be realized in one or more microprocessors,
microcontrollers, embedded microcontrollers, programmable digital
signal processors or other programmable device, along with internal
and/or external memory. The processes may also, or instead, be
embodied in an application specific integrated circuit, a
programmable gate array, programmable array logic, or any other
device or combination of devices that may be configured to process
electronic signals. It will further be appreciated that one or more
of the processes may be realized as a computer executable code
capable of being executed on a machine-readable medium.
[2223] The computer executable code may be created using a
structured programming language such as C, an object oriented
programming language such as C++, or any other high-level or
low-level programming language (including assembly languages,
hardware description languages, and database programming languages
and technologies) that may be stored, compiled or interpreted to
run on one of the above devices, as well as heterogeneous
combinations of processors, processor architectures, or
combinations of different hardware and software, or any other
machine capable of executing program instructions.
[2224] Thus, in one aspect, methods described above and
combinations thereof may be embodied in computer executable code
that, when executing on one or more computing devices, performs the
steps thereof. In another aspect, the methods may be embodied in
systems that perform the steps thereof, and may be distributed
across devices in a number of ways, or all of the functionality may
be integrated into a dedicated, standalone device or other
hardware. In another aspect, the means for performing the steps
associated with the processes described above may include any of
the hardware and/or software described above. All such permutations
and combinations are intended to fall within the scope of the
present disclosure.
[2225] While the disclosure has been disclosed in connection with
the preferred embodiments shown and described in detail, various
modifications and improvements thereon will become readily apparent
to those skilled in the art. Accordingly, the spirit and scope of
the present disclosure is not to be limited by the foregoing
examples, but is to be understood in the broadest sense allowable
by law.
[2226] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the disclosure (especially
in the context of the following claims) is to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the disclosure, and does not
pose a limitation on the scope of the disclosure unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the disclosure.
[2227] Implementations of approaches described above may include
software implementations, which use software instructions stored on
non-transitory machine-readable media. The procedures and protocols
as described above in the text and figures are sufficient for one
skilled in the art to implement them in such software
implementations. In some examples, the software may execute on a
client node (e.g., a smartphone) using a general-purpose processor
that implements a variety of functions on the client node. Software
that executes on end nodes or intermediate network nodes may use
processors that are dedicated to processing network traffic, for
example, being embedded in network processing devices. In some
implementations, certain functions may be implemented in hardware,
for example, using Application-Specific Integrated Circuits
(ASICs), and/or Field Programmable Gate Arrays (FPGAs), thereby
reducing the load on a general purpose processor.
[2228] Note that in some diagrams and figures in this disclosure,
networks such as the internet, carrier networks, internet service
provider networks, local area networks (LANs), metro area networks
(MANs), wide area networks (WANs), storage area networks (SANs),
backhaul networks, cellular networks, satellite networks and the
like, may be depicted as clouds. Also note, that certain processes
may be referred to as taking place in the cloud and devices may be
described as accessing the cloud. In these types of descriptions,
the cloud should be understood to be some type of network
comprising networking equipment and wireless and/or wired
links.
[2229] The description above may refer to a client device
communicating with a server, but it should be understood that the
technology and techniques described herein are not limited to those
exemplary devices as the end-points of communication connections or
sessions. The end-points may also be referred to as, or may be,
senders, transmitters, transceivers, receivers, servers, video
servers, content servers, proxy servers, cloud storage units,
caches, routers, switches, buffers, mobile devices, tablets, smart
phones, handsets, computers, set-top boxes, modems, gaming systems,
nodes, satellites, base stations, gateways, satellite ground
stations, wireless access points, and the like. The devices at any
of the end-points or intermediate nodes of communication
connections or sessions may be commercial media streaming boxes
such as those implementing Apple TV, Roku, Chromecast, Amazon Fire,
Slingbox, and the like, or they may be custom media streaming
boxes. The devices at the any of the end-points or intermediate
nodes of communication connections or sessions may be smart
televisions and/or displays, smart appliances such as hubs,
refrigerators, security systems, power panels and the like, smart
vehicles such as cars, boats, busses, trains, planes, carts, and
the like, and may be any device on the Internet of Things (IoT).
The devices at any of the end-points or intermediate nodes of
communication connections or sessions may be single-board computers
and/or purpose built computing engines comprising processors such
as ARM processors, video processors, system-on-a-chip (SoC), and/or
memory such as random access memory (RAM), read only memory (ROM),
or any kind of electronic memory components.
[2230] Communication connections or sessions may exist between two
routers, two clients, two network nodes, two servers, two mobile
devices, and the like, or any combination of potential nodes and/or
end-point devices. In many cases, communication sessions are
bi-directional so that both end-point devices may have the ability
to send and receive data. While these variations may not be stated
explicitly in every description and exemplary embodiment in this
disclosure, it should be understood that the technology and
techniques we describe herein are intended to be applied to all
types of known end-devices, network nodes and equipment and
transmission links, as well as to future end-devices, network nodes
and equipment and transmission links with similar or improved
performance.
[2231] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software,
program codes, and/or instructions on a processor. The present
disclosure may be implemented as a method on the machine, as a
system or apparatus as part of or in relation to the machine, or as
a computer program product embodied in a computer readable medium
executing on one or more of the machines. In embodiments, the
processor may be part of a server, cloud server, client, network
infrastructure, mobile computing platform, stationary computing
platform, or other computing platforms. A processor may be any kind
of computational or processing device capable of executing program
instructions, codes, binary instructions, and the like. The
processor may be or may include a signal processor, digital
processor, embedded processor, microprocessor, or any variant such
as a co-processor (math co-processor, graphic co-processor,
communication co-processor, and the like) and the like that may
directly or indirectly facilitate execution of program code or
program instructions stored thereon. In addition, the processor may
enable execution of multiple programs, threads, and codes. The
threads may be executed simultaneously to enhance the performance
of the processor and to facilitate simultaneous operations of the
application. By way of implementation, methods, program codes,
program instructions and the like described herein may be
implemented in one or more thread. The thread may spawn other
threads that may have assigned priorities associated with them; the
processor may execute these threads based on priority or any other
order based on instructions provided in the program code. The
processor, or any machine utilizing one, may include non-transitory
memory that stores methods, codes, instructions, and programs as
described herein and elsewhere. The processor may access a
non-transitory storage medium through an interface that may store
methods, codes, and instructions as described herein and elsewhere.
The storage medium associated with the processor for storing
methods, programs, codes, program instructions or other type of
instructions capable of being executed by the computing or
processing device may include but may not be limited to one or more
of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache,
and the like.
[2232] A processor may include one or more cores that may enhance
speed and performance of a multiprocessor. In embodiments, the
process may be a dual core processor, quad core processors, other
chip-level multiprocessor and the like that combine two or more
independent cores (called a die).
[2233] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software
on a server, client, firewall, gateway, hub, router, or other such
computer and/or networking hardware. The software program may be
associated with a server that may include a file server, print
server, domain server, internet server, intranet server, cloud
server, and other variants such as secondary server, host server,
distributed server, and the like. The server may include one or
more of memories, processors, computer readable transitory and/or
non-transitory media, storage media, ports (physical and virtual),
communication devices, and interfaces capable of accessing other
servers, clients, machines, and devices through a wired or a
wireless medium, and the like. The methods, programs, or codes as
described herein and elsewhere may be executed by the server. In
addition, other devices required for execution of methods as
described in this application may be considered as a part of the
infrastructure associated with the server.
[2234] The server may provide an interface to other devices
including, without limitation, clients, other servers, printers,
database servers, print servers, file servers, communication
servers, distributed servers, social networks, and the like.
Additionally, this coupling and/or connection may facilitate remote
execution of program across the network. The networking of some or
all of these devices may facilitate parallel processing of a
program or method at one or more location without deviating from
the scope of the disclosure. In addition, any of the devices
attached to the server through an interface may include at least
one storage medium capable of storing methods, programs, code
and/or instructions. A central repository may provide program
instructions to be executed on different devices. In this
implementation, the remote repository may act as a storage medium
for program code, instructions, and programs.
[2235] The software program may be associated with a client that
may include a file client, print client, domain client, internet
client, intranet client and other variants such as secondary
client, host client, distributed client, and the like. The client
may include one or more of memories, processors, computer readable
transitory and/or non-transitory media, storage media, ports
(physical and virtual), communication devices, and interfaces
capable of accessing other clients, servers, machines, and devices
through a wired or a wireless medium, and the like. The methods,
programs, or codes as described herein and elsewhere may be
executed by the client. In addition, other devices required for
execution of methods as described in this application may be
considered as a part of the infrastructure associated with the
client.
[2236] The client may provide an interface to other devices
including, without limitation, servers, other clients, printers,
database servers, print servers, file servers, communication
servers, distributed servers, and the like. Additionally, this
coupling and/or connection may facilitate remote execution of
program across the network. The networking of some or all of these
devices may facilitate parallel processing of a program or method
at one or more location without deviating from the scope of the
disclosure. In addition, any of the devices attached to the client
through an interface may include at least one storage medium
capable of storing methods, programs, applications, code and/or
instructions. A central repository may provide program instructions
to be executed on different devices. In this implementation, the
remote repository may act as a storage medium for program code,
instructions, and programs.
[2237] The methods and systems described herein may be deployed in
part or in whole through network infrastructures. The network
infrastructure may include elements such as computing devices,
servers, routers, hubs, firewalls, clients, personal computers,
communication devices, routing devices and other active and passive
devices, modules and/or components as known in the art. The
computing and/or non-computing device(s) associated with the
network infrastructure may include, apart from other components, a
storage medium such as flash memory, buffer, stack, RAM, ROM, and
the like. The processes, methods, program codes, instructions
described herein and elsewhere may be executed by one or more of
the network infrastructural elements. The methods and systems
described herein may be adapted for use with any kind of private,
community, or hybrid cloud computing network or cloud computing
environment, including those which involve features of software as
a service ("SaaS"), platform as a service ("PaaS"), and/or
infrastructure as a service ("IaaS").
[2238] The methods, program codes, and instructions described
herein and elsewhere may be implemented on a cellular network
having multiple cells. The cellular network may either be frequency
division multiple access ("FDMA") network or code division multiple
access ("CDMA") network. The cellular network may include mobile
devices, cell sites, base stations, repeaters, antennas, towers,
and the like. The cell network may be a GSM, GPRS, 3G, EVDO, mesh,
or other networks types.
[2239] The methods, program codes, and instructions described
herein and elsewhere may be implemented on or through mobile
devices. The mobile devices may include navigation devices, cell
phones, mobile phones, mobile personal digital assistants, laptops,
palmtops, netbooks, pagers, electronic books readers, music players
and the like. These devices may include, apart from other
components, a storage medium such as a flash memory, buffer, RAM,
ROM and one or more computing devices. The computing devices
associated with mobile devices may be enabled to execute program
codes, methods, and instructions stored thereon. Alternatively, the
mobile devices may be configured to execute instructions in
collaboration with other devices. The mobile devices may
communicate with base stations interfaced with servers and
configured to execute program codes. The mobile devices may
communicate on a peer-to-peer network, mesh network, or other
communications network. The program code may be stored on the
storage medium associated with the server and executed by a
computing device embedded within the server. The base station may
include a computing device and a storage medium. The storage device
may store program codes and instructions executed by the computing
devices associated with the base station.
[2240] The computer software, program codes, and/or instructions
may be stored and/or accessed on machine readable transitory and/or
non-transitory media that may include: computer components,
devices, and recording media that retain digital data used for
computing for some interval of time; semiconductor storage known as
random access memory ("RAM"); mass storage typically for more
permanent storage, such as optical discs, forms of magnetic storage
like hard disks, tapes, drums, cards and other types; processor
registers, cache memory, volatile memory, non-volatile memory;
optical storage such as CD, DVD; removable media such as flash
memory (e.g. USB sticks or keys), floppy disks, magnetic tape,
paper tape, punch cards, standalone RAM disks, zip drives,
removable mass storage, off-line, and the like; other computer
memory such as dynamic memory, static memory, read/write storage,
mutable storage, read only, random access, sequential access,
location addressable, file addressable, content addressable,
network attached storage, storage area network, bar codes, magnetic
ink, and the like.
[2241] The methods and systems described herein may transform
physical and/or intangible items from one state to another. The
methods and systems described herein may also transform data
representing physical and/or intangible items from one state to
another.
[2242] The elements described and depicted herein, including in
flow charts and block diagrams throughout the figures, imply
logical boundaries between the elements. However, according to
software or hardware engineering practices, the depicted elements
and the functions thereof may be implemented on machines through
computer executable transitory and/or non-transitory media having a
processor capable of executing program instructions stored thereon
as a monolithic software structure, as standalone software modules,
or as modules that employ external routines, code, services, and so
forth, or any combination of these, and all such implementations
may be within the scope of the present disclosure. Examples of such
machines may include, but may not be limited to, personal digital
assistants, laptops, personal computers, mobile phones, other
handheld computing devices, medical equipment, wired or wireless
communication devices, transducers, chips, calculators, satellites,
tablet PCs, electronic books, gadgets, electronic devices, devices
having artificial intelligence, computing devices, networking
equipment, servers, routers, and the like. Furthermore, the
elements depicted in the flow chart and block diagrams or any other
logical component may be implemented on a machine capable of
executing program instructions. Thus, while the foregoing drawings
and descriptions set forth functional aspects of the disclosed
systems, no particular arrangement of software for implementing
these functional aspects should be inferred from these descriptions
unless explicitly stated or otherwise clear from the context.
Similarly, it will be appreciated that the various steps identified
and described above may be varied and that the order of steps may
be adapted to particular applications of the techniques disclosed
herein. All such variations and modifications are intended to fall
within the scope of this disclosure. As such, the depiction and/or
description of an order for various steps should not be understood
to require a particular order of execution for those steps, unless
required by a particular application, or explicitly stated or
otherwise clear from the context.
[2243] The methods and/or processes described above, and steps
associated therewith, may be realized in hardware, software or any
combination of hardware and software suitable for a particular
application. The hardware may include a general-purpose computer
and/or dedicated computing device or specific computing device or
particular aspect or component of a specific computing device. The
processes may be realized in one or more microprocessors,
microcontrollers, embedded microcontrollers, programmable digital
signal processors or other programmable devices, along with
internal and/or external memory. The processes may also, or
instead, be embodied in an application specific integrated circuit,
a programmable gate array, programmable array logic, or any other
device or combination of devices that may be configured to process
electronic signals. It will further be appreciated that one or more
of the processes may be realized as a computer executable code
capable of being executed on a machine-readable medium.
[2244] The computer executable code may be created using a
structured programming language such as C, an object oriented
programming language such as C++, or any other high-level or
low-level programming language (including assembly languages,
hardware description languages, and database programming languages
and technologies) that may be stored, compiled or interpreted to
run on one of the above devices, as well as heterogeneous
combinations of processors, processor architectures, or
combinations of different hardware and software, or any other
machine capable of executing program instructions.
[2245] Thus, in one aspect, methods described above and
combinations thereof may be embodied in computer executable code
that, when executing on one or more computing devices, performs the
steps thereof. In another aspect, the methods may be embodied in
systems that perform the steps thereof, and may be distributed
across devices in a number of ways, or all of the functionality may
be integrated into a dedicated, standalone device or other
hardware. In another aspect, the means for performing the steps
associated with the processes described above may include any of
the hardware and/or software described above. All such permutations
and combinations are intended to fall within the scope of the
present disclosure.
[2246] While the disclosure has been disclosed in connection with
the preferred embodiments shown and described in detail, various
modifications and improvements thereon will become readily apparent
to those skilled in the art. Accordingly, the spirit and scope of
the present disclosure is not to be limited by the foregoing
examples but is to be understood in the broadest sense allowable by
law.
[2247] The use of the terms "a," "an." and "the" and similar
referents in the context of describing the disclosure (especially
in the context of the following claims) is to be construed to cover
both the singular and the plural unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitations of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein may be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the disclosure and does not
pose a limitation on the scope of the disclosure unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the disclosure.
[2248] Any element in a claim that does not explicitly state "means
for" performing a specified function, or "step for" performing a
specified function, is not to be interpreted as a "means" or "step"
clause as specified in 35 U.S.C. .sctn. 112(f). In particular, any
use of "step of" in the claims is not intended to invoke the
provision of 35 U.S.C. .sctn. 112(f).
[2249] Persons of ordinary skill in the art may appreciate that
numerous design configurations may be possible to enjoy the
functional benefits of the inventive systems. Thus, given the wide
variety of configurations and arrangements of embodiments of the
present invention the scope of the invention is reflected by the
breadth of the claims below rather than narrowed by the embodiments
described above.
[2250] It is to be understood that the foregoing description is
intended to illustrate and not to limit the scope of the invention,
some aspects of which are defined by the scope of the appended
claims. Furthermore, other embodiments are within the scope of the
following claims.
* * * * *
References