The field of the invention relates generally to displaying information, and more particularly to methods and systems for use in identifying a malfunction in a machine or other asset based on a plot of data collected from the asset.
In a facility in which resources are received, processed, and converted by machines into electricity or another product, it is often beneficial to monitor the status of the machines to determine whether they are operating normally. To facilitate such monitoring, in at least some facilities, sensors are positioned adjacent to such machines to measure one or more parameters or characteristics, such as vibrations, temperatures, voltages or currents associated with the machines. In some environments with multiple machines and multiple sensors, the information collected by the sensors is transmitted to a central computer for evaluation by the computer and/or a user of the computer. Additionally, the information may be stored in a database and reviewed on an as-needed basis.
Data stored as described above may relate to a particular type of measurement for a particular machine. The data may indicate the existence of a malfunction in the machine. However, identifying the existence and nature of a malfunction from the data, even when the data is displayed in a plot, can be difficult for those who are not familiar with the machine or diagnostic analysis per plot and data type.
In one aspect, a method for correlating data collected from at least one sensor of a first machine of a first type with a malfunction of the first machine is provided. The method is implemented by a computing device. The method includes storing, in a memory coupled to the computing device, an analysis data set based on measurement information from the at least one sensor. The method further includes storing, in the memory, at least one reference data set corresponding with a malfunction of a second machine, the second machine being of the first type. Additionally, the method includes displaying, with a display device, a first plot representing the analysis data set. Further, the method includes displaying, with the display device, a second plot representing one reference data set of the at least one reference data set.
In another aspect, a computing device for correlating data collected from at least one sensor of a first machine of a first type with a malfunction of the first machine is provided. The computing device includes a processor, a display device coupled to the processor, and a memory coupled to the processor. The memory contains processor-executable instructions for performing the steps of storing, in the memory, an analysis data set based on measurement information from the at least one sensor and storing, in the memory, at least one reference data set corresponding with a malfunction of a second machine, the second machine being of the first type. The memory further contains processor-executable instructions for displaying, with the display device, a first plot representing the analysis data set and displaying, with the display device, a second plot representing one reference data set of the at least one reference data set.
In another aspect, a system for correlating data collected from at least one sensor of a first machine of a first type with a malfunction of said first machine is provided. The system includes at least one sensor, the first machine, a computing device comprising a processor, a display device coupled to the processor, and a memory coupled to the processor. The memory contains processor-executable instructions for performing the steps of storing, in the memory, an analysis data set based on measurement information from said at least one sensor and storing, in the memory, at least one reference data set corresponding with a malfunction of a second machine, the second machine being of the first type. The memory further contains processor-executable instructions for displaying, with the display device, a first plot representing the analysis data set and displaying, with the display device, a second plot representing one reference data set of at least one reference data set.
Sensors 114, 116, and 118 are communicatively coupled to machine 102. In the exemplary embodiment, sensor 114 measures a temperature of machine 102, sensor 116 measures a vibration of machine 102, and sensor 118 measures a voltage of machine 102. Likewise, sensors 120, 122, and 124 are also communicatively coupled to machine 104. In the exemplary embodiment, sensor 120 measures a temperature of machine 104, sensor 122 measures a vibration of machine 104, and sensor 124 measures a voltage of machine 104. Sensors 126, 128, and 130 are communicatively coupled to machine 108. Sensor 126 measures a temperature of machine 108, sensor 128 measures a vibration of machine 108, and sensor 130 measures a voltage of machine 108. Additionally, sensors 132, 134, and 136 are also communicatively coupled to machine 110 to enable sensor 132 to measure a temperature of machine 110, sensor 134 to measure a vibration of machine 110, and sensor 136 to measure a voltage of machine 110.
An intermediate server system 138 is communicatively coupled to sensors 114, 116, 118, 120, 122, and 124. Intermediate server system 138 includes a database server 140 that stores and retrieves information in a database 142. Intermediate server system 138 receives measurement data from sensors 114, 116, 118, 120, 122, and 124 and causes database server 140 to store the received measurement data in database 142. Similarly, an intermediate server system 144 is communicatively coupled to sensors 126, 128, 130, 132, 134, and 136. Intermediate server system 144 includes a database server 146 that stores and retrieves information in a database 148. Intermediate server system 144 receives measurement data from sensors 126, 128, 130, 132, 134, and 136 and causes database server 146 to store the received measurement data in database 148.
A central server system 150 is coupled to intermediate server systems 138 and 144. Similar to intermediate server systems 138 and 144, central server system 150 includes a database server 152 that stores and retrieves information in a database 154. Central server system 150 transmits instructions to intermediate server systems 138 and 144 to provide measurement data stored in databases 142 and 148, respectively, for storage in database 154. In the exemplary embodiment, central server system 150 transmits instructions and receives the corresponding measurement data at regular intervals, for example, daily. In the exemplary embodiment, for efficiency, the transmissions from central server system 150 ensure that only measurement information that has been added or updated since the previous time the intermediate server systems 138 and 144 provided measurement information to central server system 150 are transmitted to central server system 150. After receiving the measurement information from intermediate server systems 138 and 144, central server system 150 causes database server 152 to store the received measurement information in database 154. Other embodiments may include a different number of sensors and/or sensors that may measure different characteristics or behaviors of one or more machines. Additionally, in alternative embodiments, there are no intermediate server systems and all sensors are coupled to a central server system. In yet other embodiments, all sensors are coupled to a single computing device.
Each workstation, 238, 240, and 242, is a computing device that includes a web browser. Although the functions performed at the workstations are typically illustrated as being performed at respective workstations 238, 240, and 242, such functions can be performed at one of many computing devices coupled to LAN 236. Workstations 238, 240, and 242 are illustrated as being associated with separate functions only to facilitate an understanding of the different types of functions that can be performed by individuals having access to LAN 236.
Central server system 150 is configured to be communicatively coupled to entities outside LAN 236 as well, such as workstations 254 and 256 via an Internet connection 248. The communication in the exemplary embodiment is illustrated as being performed using the Internet, however, any other wide area network (WAN) type communication can be utilized in other embodiments, i.e., the systems and processes are not limited to being practiced using the Internet. In addition, and rather than WAN 250, local area network 236 could be used in place of WAN 250.
In the exemplary embodiment, any authorized individual or entity having a workstation 238, 240, 242, 254, 256 may access system 200. At least one of the client systems includes a manager workstation 256 located at a remote location. Workstations 254 and 256 include a computing device having a web browser. Also, workstations 254 and 256 are configured to communicate with server system 150. Furthermore, fax server 228 is configured to communicate with remotely located client systems 222 using a telephone link.
Computing device 302 also includes at least one media output component 315 for presenting information to user 301. Media output component 315 is any component capable of conveying information to user 301. In some embodiments, media output component 315 includes an output adapter such as a video adapter and/or an audio adapter. An output adapter is operatively coupled to processor 305 and operatively couplable to an output device such as a display device (e.g., a liquid crystal display (LCD), organic light emitting diode (OLED) display, cathode ray tube (CRT), or “electronic ink” display) or an audio output device (e.g., a speaker or headphones). In some embodiments, at least one such display device and/or audio device is included in media output component 315.
In some embodiments, computing device 302 includes an input device 320 for receiving input from user 301. Input device 320 may include, for example, a keyboard, a pointing device, a mouse, a stylus, a touch sensitive panel (e.g., a touch pad or a touch screen), a gyroscope, an accelerometer, a position detector, or an audio input device. A single component such as a touch screen may function as both an output device of media output component 315 and input device 320.
Computing device 302 may also include a communication interface 325, which is communicatively couplable to a remote computing device such as a server system 138, 144, 150 or a client system 222. Communication interface 325 may include, for example, a wired or wireless network adapter or a wireless data transceiver for use with a mobile phone network (e.g., Global System for Mobile communications (GSM), 3G, 4G or Bluetooth) or other mobile data network (e.g., Worldwide Interoperability for Microwave Access (WIMAX)).
Stored in memory area 310 are, for example, processor-executable instructions for providing a user interface to user 301 via media output component 315 and, optionally, receiving and processing input from input device 320. A user interface may include, among other possibilities, a web browser and client application. Web browsers enable users, such as user 301, to display and interact with media and other information typically embedded on a web page or a website from a server system, for example central server system 150. A client application allows a user, such as user 301, to display and interact with a server system, such as central server system 150, in a manner that does not necessarily involve a web page or website and which may offload more storage and/or processing functions to the client application from the server system.
Memory area 310 may include, but is not limited to, any computer-operated hardware suitable for storing and/or retrieving processor-executable instructions and/or data. Memory area 310 may include random access memory (RAM) such as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and non-volatile RAM (NVRAM). Further, memory area 310 may include multiple storage units such as hard disks or solid state disks in a redundant array of inexpensive disks (RAID) configuration. Memory area 310 may include a storage area network (SAN) and/or a network attached storage (NAS) system. In some embodiments, memory area 310 includes memory that is integrated in computing device 302. For example, computing device 302 may include one or more hard disk drives as memory 310. Memory area 310 may also include memory that is external to computing device 302 and may be accessed by a plurality of computing devices 302. The above memory types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a processor-executable instructions and/or data.
Stored in memory area 310 (shown in
In one embodiment, the steps of method 700 are carried out exclusively by central server system 150 (shown in
A technical effect of systems and methods described herein includes at least one of: (a) storing, in a memory of a computing device, an analysis data set based on measurement information from the at least one sensor; (b) storing, in the memory, at least one reference data set corresponding with a malfunction of a second machine, the second machine being of the first type; (c) displaying, with a display device of a computing device, a first plot representing the analysis data set; and (d) displaying, with the display device, a second plot representing one reference data set of the at least one reference data set.
As compared to known methods and systems for plotting data collected from a sensor of a machine, the methods and systems described herein generate plots that more easily allow a user to perceive that a specific malfunction has occurred in the machine. Exemplary embodiments of methods and systems for plotting such data are described above in detail. The methods and systems described herein are not limited to the specific embodiments described herein, but rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.