The present disclosure relates to methods and systems that provide for operational surveillance of physical assets, such as industrial equipment, devices, systems, and processes.
Current methods and systems that perform operational surveillance of physical assets (such as industrial equipment, devices, systems, and processes) face several challenges, including the following: i) configuring and maintaining rule-based alerts or alarms on sensor data (i.e., threshold high-temperature alarm); and ii) for more advanced analytics, the population of a relevant data set for model training is time-consuming.
The configuration of a rule-based alert or alarm is typically based on logic that involves one or more thresholds of operational data, such as high or low limits of time-series data measured by one or more sensors. The intention is that when the time-series data is above/below a specific value, the data reflects a symptom of an operational state change with regard to an associated physical asset (such as failure or changing operating conditions of the associated physical asset). In this manner, the operational state change of the physical asset can be detected by identifying that the corresponding threshold in the time-series data has been crossed. Whenever the threshold is crossed (and thus the operational state change of the physical asset has been detected), an alert or alarm can be raised, and the alert or alarm can be communicated to one or more users in order to inform such user(s) of the corresponding operational state change. Some of the challenges with such systems are alarm management, as it can populate a significant number of alerts from a varying and noisy input signal, and the threshold limit might have to be changed multiple times over the lifetime of a physical asset.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
In an embodiment, a method for monitoring operation or status of a physical asset is described. The method includes: i) receiving or collecting time-series data related to operation or status of the physical asset; ii) identifying a time period when the physical asset is experiencing a change of operational state; iii) extracting time-series data corresponding to the time period of ii) as event data; iv) generating label data that classifies or characterizes the event data of iii) as pertaining to a particular type of event; v) saving the event data of iii) and the corresponding label data of iv) in a data repository; and vi) using the event data and label data stored in the data repository in v) to train or update a machine learning system to detect the occurrence of events that are similar to the event types of the labeled event data stored in the data repository from time-series data generated by the physical asset or by another physical asset that operates in a similar manner to the physical asset.
In another embodiment, a system for monitoring operation or status of a physical asset is described. The system includes at least one processor configured to perform operations that involve i) receiving or collecting time-series data related to operation or status of the physical asset; ii) identifying a time period when the physical asset is experiencing a change of operational state; iii) extracting time-series data corresponding to the time period of ii) as event data; iv) generating label data that classifies or characterizes the event data of iii) as pertaining to a particular type of event; v) saving the event data of iii) and the corresponding label data of iv) in a data repository; and vi) using the event data and label data stored in the data repository in v) to train or update a machine learning system to detect the occurrence of events that are similar to the event types of the labeled event data stored in the data repository from time-series data generated by the physical asset or by another physical asset that operates in a similar manner to the physical asset.
Further features and advantages of the subject disclosure will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
The subject disclosure is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of embodiments of the subject disclosure, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings and figures. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
It will also be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first object or step could be termed a second object or step, and, similarly, a second object or step could be termed a first object or step, without departing from the scope of the invention. The first object or step, and the second object or step, are both, objects or steps, respectively, but they are not to be considered the same object or step.
The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Further, as used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context.
Attention is now directed to processing procedures, methods, techniques, and workflows that are in accordance with some embodiments. Some operations in the processing procedures, methods, techniques, and workflows disclosed herein may be combined and/or the order of some operations may be changed.
Methods and systems are provided for monitoring operation or status of a physical asset, which involve receiving or collecting time-series data related to operation or status of the physical asset. A time period when the physical asset is experiencing a change of operational state is identified, preferably by user interaction with a graphical user interface that displays the received or collected time-series data. Time-series data corresponding to the identified time period is extracted as event data. Label data that classifies or characterizes the event data as pertaining to a particular type of event is generated, preferably by user interaction with a graphical user interface that displays the received or collected time-series data or associated event data. The event data and corresponding label data can be stored in a data repository and used to train or update a machine learning system to detect the occurrence of events that are similar to the event types of the labeled event data stored in the data repository from time-series data generated by the physical asset or by another physical asset that operates in a similar manner to the physical asset. The machine learning system can be trained to perform pattern recognition on future time-series data to detect or find similar events in the future time-series data, and/or the machine learning system can be used to perform pattern recognition in past time-series data to detect or find similar events in the past time-series data. The event data corresponding to a similar event in the future or past time-series data can be used to further train the machine learning system to incrementally improve its capabilities and continuously identify when new similar events occur.
The present disclosure provides methods and systems of operational surveillance of physical assets (such as industrial equipment, devices, systems, and processes) that address the challenges and limitations of the prior art methods and systems. Specifically, threshold alerts and alarm(s) for one or more sensor measurements can be avoided. Instead, a user (who is referred to as a “developer user” herein and can be one or more data scientists or other users responsible for developing and/or maintaining the methodology and system) can select a time period when the physical asset is experiencing a particular change of operational state (i.e., start-up, shut-in, high/low vibration, flow change, etc.). Time-series data (e.g., real-time operational data) that characterizes operation of the physical asset during the selected time period (where such time-series data is referred to as event data herein) can be collected or extracted, and label data that classifies or characterizes the event data as pertaining to a particular type of event can be generated. The event data along with the corresponding label data can be stored in a database or other data repository, and then used to train or update a machine learning system to detect the occurrence of events that are similar to the event types of the labeled event data stored in the data repository from time-series data generated by the same physical asset (or by another physical asset that operates in a similar manner to the physical asset). In embodiments, the machine learning system can be trained to perform pattern recognition (e.g., univariate pattern recognition) on future time-series data to detect or find similar events in the future time-series data. The trained machine learning system can also be used to perform pattern recognition on past time-series data to detect or find similar events in the past time-series data. The event data corresponding to a similar event in the future or past time-series data can be used to further train the machine learning system to incrementally improve its capabilities and continuously identify when new similar events occur.
The developer user can specify features or characteristics of the event data that is stored into the data repository for which the developer user would like to be notified. For example, such features can represent duration of the underlying event, frequency of the underlying event, first occurrence of the underlying event, etc. Such features or characteristics can be used to process and filter the event data stored in the data repository over time to extract the corresponding event data and then provide notification of the availability of such event data. The developer user can use the available event data to train the machine learning system to incrementally improve its capabilities and continuously identify when new similar events occur. In this manner, a cognitive surveillance system is provided where the developer user can train the machine learning system to fit particular needs based on what changes are important to be notified on.
Furthermore, the methods and systems can be adapted such that multiple developer users can contribute event data and label data to the data repository. This can facilitate crowdsourcing of labeled events in a common repository, accessible as pre-processed training data set for the developer users to develop more advanced machine learning models for operational surveillance.
In embodiments, the methods and systems described herein can employ a distributed computing platform for operational surveillance of a physical asset, as shown in
The cloud services 19 include services that monitor operating conditions and status of the physical asset 13, which is referred to as operational surveillance of the physical asset 13. Such services are typically embodied by software executing in a computing environment, such as a cloud computing environment. In embodiments, the cloud computing environment can be configured to deliver different resources through data communication over the Internet. Such resources can include tools and computing services, such as data storage, servers, databases, networking, and software. Examples of commercially available cloud computing environments include the Azure cloud services offered by Microsoft of Redmond, Washington, the AWS cloud services offered by Amazon Web Services, Inc. of Seattle, Washington, and the Google Cloud Services offered by Google of Mountain View, California. An example computing environment is described below with respect to
In block 201, time-series data (e.g., real-time operational data) derived from sensor measurements and related to operation or status of a physical asset (e.g., industrial equipment, device, system, or process) is received or collected. In embodiments, such time-series data (e.g., real-time operational data) can be communicated from a gateway device associated with the physical asset, such as the gateway device 11 associated with physical asset 13 of
In block 203, a user (e.g., developer user) can select a time period when the physical asset is experiencing a particular change of operational state (i.e., start-up, shut-in, high/low vibration, flow change, etc.). The event can relate to any behavior of the physical asset that the user wants to track or be notified of. In embodiments, the event can be described by a particular label or event type that belongs to one or two event categories; cyclic events and anomaly events. For example, labels or event types for cyclic events can represent valve actuation, pump trip, shut-in periods, shut-downs, pump on-off, tank refilling, etc. Anomaly events are events that are not supposed to happen. For example, labels or event types for anomaly events can represent leaks, overpressure, failure, etc.
In block 205, the time-series data corresponding to the selected time period/event is extracted from the time-series data as event data, and the user generates label data that classifies or characterizes the event data as pertaining to a particular type of event. The event data along with the corresponding label data is stored in a database or other data repository.
In block 207, the event data and corresponding label data stored in the data repository can be used to train or update a machine learning system to detect the occurrence of events that are similar to the event types of the labeled event data stored in the data repository from time-series data generated by the same physical asset (or by another physical asset that operates in a similar manner to the physical asset).
In block 209, the trained machine learning system can be used to perform pattern recognition (e.g., univariate pattern recognition) on past time-series data to detect or find similar events in the past time-series data. In block 211, the trained machine learning system can be used to perform pattern recognition (e.g., univariate pattern recognition) on future time-series data to detect or find similar events in the future time-series data. The event data corresponding to a similar event in the future or past time-series data can be used to further train the machine learning system to incrementally improve its capabilities and continuously identify when new similar events occur. In embodiments, the machine learning system can employ a computation model that uses machine learning and/or pattern recognition to identify a pattern of one event type (with one or more instances in the set) in univariate time-series data supplied as input to the computational model. In embodiments, the machine learning system can be configured to learn and adapt without following explicit instructions, by using algorithms and statistical models to analyze and draw inferences from patterns in the time-series data supplied as input to the system. In embodiments, the machine learning system can employ one or more computational models, such as an artificial neural network, a decision tree model, a support-vector machine, regression analysis, and a Bayesian network.
Users (e.g., one or more developer users) can specify features or characteristics of the event data that is stored into the data repository for which they would like to be notified. For example, such features can represent duration of the underlying event, frequency of the underlying event, first occurrence of the underlying event, etc. In embodiments, such features or characteristics can be used to process and filter the event data stored in the data repository to extract the corresponding event data. In block 213, the user can be notified of the availability of the corresponding event data. The user can use the available event data to train the machine learning system to incrementally improve its capabilities and continuously identify when new similar events occur. In this manner, a cognitive surveillance system is provided where a user can train the machine learning system to fit the user's particular need based on what changes are important to be notified on.
Furthermore, the workflow of
In embodiments, the methods and systems described herein can be configured to enable a user (e.g., developer user) to identify or select an event within time-series data utilizing a graphical user interface based on a set of tags (e.g., data streams). An example of such a graphical user interface is illustrated in
In some embodiments, the methods of the present disclosure may be executed by a computing system.
A processor may include a microprocessor, microcontroller, processor module or subsystem, programmable integrated circuit, programmable gate array, or another control or computing device.
The storage media 406 may be implemented as one or more computer-readable or machine-readable storage media. Note that while in the example embodiment of
It should be appreciated that computing system 400 is only one example of a computing system, and that computing system 400 may have more or fewer components than shown, may combine additional components not depicted in the example embodiment of
Further, the steps in the processing methods and workflows described herein may be implemented by running one or more functional modules in information processing apparatus such as general-purpose processors or application specific chips, such as ASICs, FPGAs, PLDs, or other appropriate devices. These modules, combinations of these modules, and/or their combination with general hardware are all included within the scope of protection of the invention.
It is important to recognize that machine learning system that performs the operational surveillance of a physical asset may be refined in an iterative fashion; this concept is applicable to the methods discussed herein. This may include use of feedback loops executed on an algorithmic basis, such as at a computing device (e.g., computing system 400,
For explanation, the foregoing description has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
There have been described and illustrated herein several embodiments of methods and systems for monitoring operation or status of a physical asset. While particular scenarios have been disclosed, it will be appreciated that other scenarios could be used as well. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
The present disclosure claims priority from U.S. Provisional Appl. No. 63/158,930, filed on Mar. 10, 2021, herein incorporated by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2022/071016 | 3/8/2022 | WO |
Number | Date | Country | |
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63158930 | Mar 2021 | US |