Embodiments of the present invention are generally directed to a sensor module. More particularly, embodiments of the present invention are directed to a sensor module configured to be attached to a piece of equipment, such as a motor, and to obtain sensor data relevant to the piece of equipment. Embodiments of the present invention are further directed to a sensor module system, which includes a plurality of sensor modules each configured to obtain sensor data for a piece of equipment and to transmit such sensor data for further analysis.
In manufacturing, equipment health is of primary importance. Properly maintained equipment prevents manufacturing disruptions and idle workers. Properly maintained equipment also reduces downtime costs. Many manufacturing facilities incorporate the use of industrial equipment, such as motors, within their manufacturing processes. For a given manufacturing facility, the failure of one or more pieces of equipment can bring the entire manufacturing process to a halt. Unfortunately, such equipment is generally maintained and repaired only at predefined intervals or when issues are clearly manifested (e.g., upon a mechanical failure of a motor). As a result, the poor health of given piece of equipment is generally unknown until a failure occurs.
The use of sensors for monitoring various types of equipment is known. However, such previously-used sensors are generally large, cumbersome units, which are difficult to incorporate with many types of equipment. Additionally, such previously-used sensors were generally only configured to obtain a single type of information for the equipment. Such information would generally be required to be communicated via wired connection from the sensor to another device for analysis. Finally, the information obtained from one of such previously-used sensors would not typically be configured for integration with information from other sensors. As such, any resulting analysis was not sufficiently comprehensive.
In one embodiment of the present invention, there is provided a sensor module for obtaining sensor data relevant to a piece of equipment. The sensor module comprises a housing including a base. The base includes a mounting assembly for securing the sensor module to the piece of equipment. The sensor module additionally comprises a processing assembly at least partially enclosed within an interior space presented by the housing. The processing assembly includes a first temperature sensor configured to measure a temperature of the interior space of the housing. The processing assembly additionally includes a second temperature sensor configured to measure a temperature external to the housing. The processing assembly additionally includes a vibration sensor configured to measure vibrations experienced by the sensor module. The processing assembly further includes a communication element for wirelessly transmitting the sensor data.
In yet another embodiment of the present invention, there is provided a sensor module for obtaining sensor data for a piece of equipment. The sensor module comprises a housing including a base. The base includes a mounting assembly for securing the sensor module to the piece of equipment. The sensor module further includes a processing assembly at least partially enclosed within an interior space presented by the housing. The processing assembly includes a temperature sensing element configured to generate temperature data indicative of a temperature of the piece of equipment and a temperature indicative of a temperature external to the housing. The processing assembly additionally includes a vibration sensing element configured to generate vibration data indicative of vibrations experienced by the piece of equipment. The processing assembly further includes a communication element for wirelessly transmitting the sensor data.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.
Embodiments of the present invention are described herein with reference to the following drawing figures, wherein:
The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. While the drawings do not necessarily provide exact dimensions or tolerances for the illustrated components or structures, the drawings are to scale with respect to the relationships between the components of the structures illustrated in the drawings.
The following detailed description of the present invention references various embodiments. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
Broadly, embodiments of the present invention are directed to a sensor module 10, as illustrated in
As illustrated in
Beginning with the sensor module 10, as illustrated in
In more detail, the base 34 of the sensor module 10 may be formed in a generally cylindrical shape. As shown in
In some embodiments, as shown in
Remaining with
In some embodiments, the sensor module 10 may include a mounting assembly for securing the sensor module 10 to the piece of equipment motor (e.g., to the motor 12 of
With reference to
Beginning with the processing element 59, the processing element 59 may comprise one or more processors, microprocessors, microcontrollers, field programmable gate arrays (FPGAs), and the like, or combinations thereof. The processing element 59 may comprise dedicated circuitry or logic that is permanently configured, such as an application-specific integrated circuit (ASIC), or indefinitely configured, such as an FPGA, to perform certain operations. The processing element may also comprise programmable logic or circuitry that is temporarily configured by software to perform certain operations. In addition, the electronics board of the processing element 59 may include or be associated with one or more memory elements or internal levels of cache. The memory elements may also be known as a “computer-readable storage medium” and may include random access memory (RAM), read only memory (ROM), flash drive memory, hard disk drives, and the like, or combinations thereof. In some embodiments, the processing element 59 may include a computer program, such as may be stored on the memory elements. The processing element 59 may be capable of executing the computer program, which is also generally known as instructions, commands, software code, executables, applications, apps, and the like, to perform various portions of the functions and features described herein.
In general, the processing element 59 is configured to receive, process, and/or transmit data to/from the remaining components of the data processing assembly 52. For example, the processing element 59 may be in data communication with each of the communication element 54, the temperature sensing element 56, and the vibration sensing element 58. Thus, the processing element 59 will be configured to obtain sensor data from the temperature sensing element 56 and the vibration sensing element 58 and to provide such sensor data to the communications element 54. In some embodiments, the processing element 59 will be configured to process and/or format the sensor data before provisioning the sensor data to the communications element 54. As will be described in more detail below, the communications element 54 will be configured to transmit the sensor data to the gateway 16, in some embodiments wirelessly, via the local network 18.
The temperature sensing element 56 may include an internal temperature sensor for measuring a temperature within the sensor module 10 (e.g., within the interior space presented by the housing 32 of the sensor module 10). For example, the internal temperature sensor may comprise a negative temperature coefficient (NTC) thermistor, a resistance temperature detector (RTD) element, or a thermocouple. Alternatively, the internal temperature sensor may be a semiconductor-based temperature sensor configured on an integrated circuit within the electronics board of the temperature sensing element 56. In some embodiments, the temperature sensing element 56 may additionally include, or otherwise be associated with, a multimeter or voltmeter for measuring resistance, voltage, or other necessary characteristics generated by the internal temperature sensor so as to obtain temperature data therefrom. In some additional embodiments, the temperature sensing element 56 may further include an external temperature sensor for measuring a temperature external to the sensor module 10. For instance, the electronics board of the temperature sensing element 56 may include a port to which the external temperature sensor can be connected. In some embodiments, the external temperature sensor may be in the form of a Type-T thermocouple 60, as illustrated in
Turning to the vibration sensing element 58, the vibration sensing element 58 may comprise generally any type of accelerometer configured to measure accelerations (i.e., changes in velocity) and/or vibrations. The accelerometer may be integrated within the electronics board (e.g., as part of an integrated circuit) and may be in the form of a potentiometric accelerometer, a capacitive accelerometer, a piezoelectric accelerometer, a piezo-resistive accelerometer, a variable inductance accelerometer, a Hall Effect accelerometer, a magneto-resistive accelerometer, a fiber Bragg grating (FBG) accelerometer, a heated gas accelerometer, a micro-electro-mechanical system (MEMS) accelerometer, or combinations thereof. In some specific embodiments, the vibration sensing element 58 will include a three-axis accelerometer configured to sense accelerations of up to a peak value of plus/minus 20 g within a 10-4,000 Hz bandwidth. In some embodiments, the accelerometer will be configured to sense accelerations for only two of its three axes.
In some aspects of the present invention, the sensor module 10 may include alternative and/or additional of sensors than those discussed above. For example, in some embodiments, the sensor modules 10 may include humidity sensors, light sensors, wind sensors, etc. Additionally, the sensor module 10 may include sensors for measuring information related to certain operational characteristics of the piece of equipment (e.g., the motor 12) to which the sensor module 10 is attached, such as voltage, current, torque, etc.
The communications element 54 may include signal or data transmitting and receiving circuits, such as antennas, amplifiers, filters, mixers, oscillators, digital signal processors (DSPs), and the like. Thus, the communications element 54 may formed as an integrated circuit within the associated electronics board. The communications element 54 may, in some embodiments, include a microcontroller and/or microprocessor for processing and formatting data before such data is transmitted. The communication element 54 may establish communication wirelessly by utilizing radio-frequency (RF) signals and/or data that comply with communication standards such as cellular 2G, 3G, or 4G, IEEE 802.15.4 (compliant 2.4 GHz), IEEE 802.11 standard (such as WiFi), IEEE 802.16 standard (such as WiMAX), Bluetooth™, or combinations thereof. In some embodiments, the communications element 54 may be configured to transmit data via the Subnetwork Access Protocol (SNAP). In some embodiments, the data transmitted by the communication element 54 may initially be encrypted (e.g., via the processing element 59 and/or the communication element 54) and then transmitted via the SNAP protocol. The communications element 54 may, in some embodiments, include or be associated with a rotatable antenna 62, as illustrated in
To aid the data processing assembly 52 to fit within the housing 32 of the sensor module 10, certain embodiments provide for the electronics boards associated with each of the communications element 54, the temperature sensing element 56, the vibration sensing element 58, and the processing element 59 to be vertically stacked (although alternative stacking arrangements are permitted according to certain embodiments of the present invention). In more detail, as illustrated in
Furthermore, each of the of the electronics boards of the data processing assembly 52 (i.e., associated with the communications element 54, the temperature sensing element 56, the vibration sensing element 58, and the processing element 59) may be in data communication with each other via electrical wiring, so as to permit communication between each of the communications element 54, the temperature sensing element 56, the vibration sensing element 58, and the processing element 59. In some embodiments, one or more flexible printed circuit board (PCB) elements 64, as shown in
With reference to
As will be described in more detail, the data processing assembly 52 is configured to be secured within the housing 32 of the sensor module 10. In particular, at least one of the electronics boards of the data processing assembly 52 will be configured to be mounted to the flanged mating surface 39 presented on the upper end of the base 34 (See, e.g.,
In such a configuration (i.e., with the electronics board of the temperature sensing element 56 engaged with the flanged mating surface 39 of the base 34), the communications element 54 will extend upwards from the temperature sensing element 56 and above the base 34. Nevertheless, as will be described in more detail below, once the cap 36 is secured on the base 34, the communications element 54 will be enclosed within the interior space of the housing 32 of the sensor module 10, and in particular, within an interior space presented by the cap 36.
With the data processing assembly 52 secured to the base 34 in the manner described in the preceding paragraphs, the processing element 59 and the vibration sensing element 58 will extend downward from the temperature sensing element 56, such that the processing element 59 and the vibration sensing element 58 are enclosed within the interior space presented by the base 34. As shown in
Turning now to the cap 36 of the sensor module 10, as illustrated in
As was noted previously, in some embodiments, the sensor module 10 may include an antenna 62 for improving data transmission and/or receiving capabilities of the communications element 54. As shown in
Finally, the top panel of the cap 36 may be formed with an opening for receiving an electrical power source, as will be discussed in more detail below. In some embodiments, access to the opening may be provided through a lid 69, as shown in
Turning to the opening of the top panel of the cap 36 in more detail, as shown in
In operation, one or more sensor modules 10 can be secured to a piece of equipment to monitor vibrations and temperatures related to the piece of equipment. For example, as illustrated in
In alternate embodiments, the sensor module 10 may be secured in place on the piece of equipment (e.g., the motor from
Regardless, with the sensor module 10 securely held in place in engagement with the motor 12 (or other piece of equipment), the sensor module 10, as described above, is configured to obtain various types of sensor data related to the motor 12 and to transmit such data to the gateway 16. In particular, the sensor module 10 is configured to obtain vibration data indicative of the vibrations experienced by the motor 12. Such vibration data may be obtained by the vibration sensing element 58 of the sensor module 10. With the sensor module 10 secured to the motor 12, any vibration experienced by the motor 12 will be imparted to the sensor module 10. Specifically, any such vibration will be imparted to the bottom panel of the base 34, to the post 42 extending upward from the bottom panel of the base 34, and to the vibration sensing element 58 in contact with the post 42. Thus, the sensor module 10 is configured to obtain sensor data indicative of the vibrations being experienced by the motor 12.
In addition, the sensor module 10 may be configured to obtain temperature data indicative of a temperature at or near the surface of the motor 12, as well as a temperature external to the motor 12. For example, the internal temperature sensor of the temperature sensing element 56 may obtain temperature data indicative of the temperature at the surface of the motor 12. Specifically, as was noted previously, in some embodiments, the data processing assembly 52 will be positioned within the interior space of the sensor module 10 in a manner that permits the temperature sensing element 56 to be in contact with the base 34, as was previously described. Furthermore, the base 34 will, in some embodiments, be formed from a heat-conductive material, such as aluminum. As such, when the sensor module 10 is secured to the motor 12 with the bottom panel of the base 34 in contact with the surface of the piece of equipment, heat generated by the motor 12 can pass through the base 34 and to the temperature sensing element 56. The internal temperature sensor the temperature sensing element 56 can, therefore, accurately measure a surface temperature of the motor 12 even while the temperature sensing element 56 is positioned within the interior space of the sensor module 10. It should be further understood, however, that in some embodiments, the internal temperature sensor may not be configured to exactly measure the temperature of the motor 12. Nevertheless, the internal temperature sensor is generally configured to recognize temperature variations associated with corresponding temperature variations with the motor 12. Such variations may be sufficient to determine problems with the motor 12.
In addition, the external temperature sensor of the temperature sensing element 56 can be used to obtain temperature data indicative of a temperature external to the motor 12. As was noted previously, in some embodiments, the external temperature sensor may comprise a thermocouple 60 that can be extended from the housing 32 of the sensor module 10 to generally any given location spaced apart from the motor 12. As such, the external temperature sensor of the temperature sensing element 56 can obtain temperature data indicative of the external temperature at the given location. In some instances, the motor 12 (or other piece of equipment) may be associated with a piece of machinery (not shown). For example, the motor 12 may provide rotary power to a piece of machinery. In some embodiments, with the sensor module 10 connected to the motor 12, the thermocouple 60 of the sensor module 10 may be extended away from the motor 12 and into contact with the piece of machinery, such that the sensor module 10 can obtain temperature data related to the temperature of the piece of machinery. As a result, embodiments of the present invention provide for the temperature sensing element 56 of the sensor module 10 to obtain temperature data indicative of two temperatures. The first temperature may be a temperature of the surface of the motor 12, while the second temperature may be a temperature external to the motor 12. It should be understood, however, that the thermocouple 60 may, in some embodiments, be optional. For example, in some embodiments, the sensor module 10 may only include an internal temperature sensor. In some alternative, or additional, embodiments, the temperature sensing element 56 may be configured to communicatively couple with an external temperature sensor; however, such external temperature sensor may not necessarily form part of the sensor module 10.
Furthermore, as was noted above, in some embodiments, the data processing assembly 52 may be configured to obtain battery data indicative of battery characteristics (e.g., voltage) of the battery 70 that provides electrical power to the sensor module 10. In some embodiments, such battery data may be included as part of the sensor data obtained by the sensor module 10.
Furthermore still, as discussed previously, in some aspects of the present invention, the sensor module 10 may include alternative and/or additional of sensors than those discussed above. For example, in some embodiments, the sensor modules 10 may include humidity sensors, light sensors, wind sensors, etc. Additionally, the sensor module 10 may include sensors for measuring information related to certain operational characteristics of the piece of equipment (e.g., the motor 12) to which the sensor module 10 is attached, such as voltage, current, torque, etc. Any data generated by such alternative and/or additional sensors may, in some embodiments, be included as part of the sensor data.
Upon the sensor module 10 obtaining vibration data, temperature data, and/or battery data (collectively, sensor data), the sensor module 10 may perform initial processing and/or storage of the sensor data. In particular, the temperature sensing element 56 may transmit temperature data to the processing element 59, and the vibration sensing element 58 may transmit vibration data to the processing element 59. In addition, battery data may also be transmitted to the processing element 59. Once such sensor data is received, the processing element 59 may format the sensor data for transmission to the gateway 16. In particular, the processing element 59 may be configured to format the sensor data according to a SNAP protocol format, such that the communications element 54 can transmit the data to the gateway 16 over the local network 18. SNAP is a protocol for transmitting IP datagrams across IEEE 802 networks. In general, IP datagrams are digital messages sent over such networks. IP datagrams will comprise a header, which includes, inter alia, information related to the source/sender of the message, the destination/recipient of the message, a message identifier, and/or a timestamp. In addition to the header, the IP datagrams will also include a payload, which comprises the relevant message data (i.e., the sensor data) intended to be transmitted from the source to the destination. As used herein, the term “data packet” will be used to reference an IP datagram.
In view of the above, the processing element 59 may process the sensor data into a data packet formatted according to the SNAP protocol. In some embodiments, the sensor data may also be encrypted (e.g., by the processing element 59 and/or the communication element 54) when configured into the data packet. During such processing, some sensor data and/or data packets may, at least temporarily, be stored in memory elements associated with the processing element 59. Upon processing and/or formatting the sensor data into a data packet, the data packet may be provided to the communications element 54 for transmission to the gateway 16 via the local network 18. Although the above description illustrates how the processing element 59 can process and/or format the sensor data into a data packet, it should be understood that in some embodiments, the processing element 59 may provide the sensor data directly to the communication element 54, and the communication element 54 may process and/or format the sensor data into a data packet according the SNAP protocol for transmission to the gateway 16 via the local network 18.
Embodiments provide for the sensor module 10 to obtain sensor data (e.g., temperature data, vibration data, and/or battery data) according to generally any measurement interval. For example, the sensor module 10 may be configured to obtain sensor data once every second, once every minute, once every hour, etc. The configuration of the measurement interval may be established by programming the sensor module 10 via the processing element 59, which can instruct the temperature sensing element 56 and the vibration sensing element 58 when to obtain sensor data. For each set of sensor data obtained by the sensor module 10 for a given measurement interval, the sensor module 10 can create a data packet that includes sensor data representative of the set of sensor data. Alternatively, the processing element 59 may send the sensor data to the communication element 54, and the communication element 59 may process and/or format the sensor data into a data packet. Regardless, as was noted previously, such a data packet may be configured according to the SNAP protocol. As such, the data packet will comprise a header portion that defines the source (i.e., the sensor module 10), the destination (i.e., the gateway 16), the message identifier, and/or the timestamp. The data packet will additionally comprise a payload that includes sensor data for the given measurement interval. As was noted previously, in some embodiments, the sensor data within the data packet may be encrypted (e.g., via the processing element 59 and/or the communication element 54).
The message identifier for a given data packet may be used to identify the given data packet. For example, the message identifier may be in the form of a counter that increases in magnitude for each successive data packet generated/transmitted. For example, if the measurement interval is one minute, the sensor module 10 may obtain a first set of sensor data (i.e., representative of the temperature data, the vibration data, and/or the battery data obtained for the initial measurement interval). The resulting data packet will include a message identifier that identifies the data packet as being the initial data packet. For example, the message identifier may be “0001.” After one minute has elapsed, the sensor module 10 obtains a second set of sensor data (i.e., representative of the temperature data, the vibration data, and/or the battery data obtained for the second measurement interval). The sensor module 10 may generate a resultant data packet with a message identifier that identifies the data packet as the second data packet. For example, the message identifier may be “0002.” As will be discussed in more detail below, the use of message identifiers may aid the gateway 16 in processing the data packets received from the sensor module 10. Efficient processing of the data packets can enhance longevity of the sensor module 10, including the operational life of the battery 70.
Upon the generation of a data packet (each including temperature data, vibration data, and/or battery data for a given measurement interval), the sensor module 10 will be configured to transmit, via the communication element 54, such data packet to the gateway 16 via the local network 18 for further processing. In some embodiments, the sensor module 10 will transmit each data packet immediately, in real-time upon creation of the data packet. In such embodiments, the transmission rate of the sensor modules 10 will be generally equal to the measurement interval. Alternatively, in some embodiments, the sensor module 10 may aggregate the data packets over a period of time into a batch of data packets and transmit the batch of data packets to the gateway 16 over the local network 18. In addition, in some embodiments, the sensor module 10 will be configured to store each data packet and/or each set of sensor data (i.e., for each temperature measurement, vibration measurement, and/or battery measurement obtained for a given measurement interval) for a predetermined period of time. For example, in some embodiments, the sensor module 10 may store, at least temporarily, the data packets collected over a period of measurement intervals. Such storage capabilities may be beneficial for instances in which transmission problems occur, and/or when the sensor module 10 becomes disconnected from the local network 18.
The above description provides an illustration for how a single sensor module 10 can be connected to a piece of equipment (e.g., the motor 12), can obtain sensor data related to the piece of equipment, and can transmit such sensor data to the gateway 16 over the local network 18. However, as illustrated in
As discussed earlier, in some preferred embodiments, the local network 18 of the SM System 14 may be local area network (LAN) to which each of the sensor modules 10 and the gateway 16 are connected. For example, the local network 18 may be configured according to IEEE 802.15.4 (compliant 2.4 GHz) and/or IEEE 802.11 standard (such as WiFi). Beneficially, in some such embodiments, the local network 18 may be configured as a mesh network. Alternatively, the local network 18 may comprise a metro or wide area networks such as the Internet or other cloud networks. The local network 18 may preferably be wireless, but may, in some embodiments be wired. The local network 18 may include one or more servers, routers, switches, wireless receivers and transmitters, and the like, as well as electrically conductive cables or optical cables. Furthermore, the local network 18 may include cellular or mobile phone networks, as well as landline phone networks, public switched telephone networks, fiber optic networks, or the like.
The gateway 16 may be configured to receive the data packets from each of the sensor modules 10 of the SM System 14, via the local network 18, and subsequently re-transmit the resulting sensor data to the server device 20 over the wide network 22. As such, the gateway 16 may be configured to receive and process data packets from each of the sensor modules 10, and to provide resulting sensor data (as generated by the plurality of sensor modules 10) to the server device 20 over the wide network 22 for further processing. The gateway 16 may comprise generally any type of computing device with one or more processing elements, one or more memory elements, and one or more communication elements, which permit the gateway 16 to function as an intermediary so as to pass sensor data from the sensor modules 10 (as received over the local network 18) to the server device 20 (over the wide network 22).
In more detail, the gateway 16 may include a processing element in the form of one or more processors, microprocessors, microcontrollers, field programmable gate arrays (FPGAs), and the like, or combinations thereof. The processing element may comprise dedicated circuitry or logic that is permanently configured, such as an application-specific integrated circuit (ASIC), or indefinitely configured, such as an FPGA, to perform certain operations. The processing element may also comprise programmable logic or circuitry that is temporarily configured by software to perform certain operations. In addition, the gateway 16 may include or be associated with one or more memory elements or internal levels of cache. The memory elements may also be known as a “computer-readable storage medium” and may include random access memory (RAM), read only memory (ROM), flash drive memory, hard disk drives, and the like, or combinations thereof. In some embodiments, the gateway 16 may be software defined, such as a computer program configured to perform the above-described tasks, e.g., similar to a default gateway or a router.
The gateway's 16 communication element may include signal or data transmitting and receiving circuits, such as antennas, amplifiers, filters, mixers, oscillators, digital signal processors (DSPs), and the like. The communication element of the gateway 16 may establish communication wirelessly by utilizing radio-frequency (RF) signals and/or data that comply with communication standards such as cellular 2G, 3G, or 4G, IEEE 802.15.4 (compliant 2.4 GHz), IEEE 802.11 standard (such as WiFi), IEEE 802.16 standard (such as WiMAX), Bluetooth™, or combinations thereof. In some embodiments, the communication element gateway 16 may be configured to receive, process, and/or transmit data via SNAP protocol. Alternatively, or additionally, the communication element of the gateway 16 may establish communication through connectors or couplers (e.g., Ethernet or USB) that receive metal conductor wires or cables which are compatible with networking technologies. In certain embodiments, the communication element of the gateway 16 may also couple with optical fiber cables.
In operation, the gateway 16 will be configured to receive each of the data packets transmitted by each of the sensor modules 10 included in the SM System 14. For example, the SM System 14 may include three sensor modules 10, with each sensor module 10 being secured to an individual piece of equipment (e.g., a motor similar to the motor 12 of
The gateway 16 will be configured to collect the data packets from each of the sensor modules 10 in the SM System 14 and to transmit the resulting sensor data from the sensor module 10 to the server device 20 over the wide network 22. In some embodiments, the gateway 16 may process and/or format the sensor data within the data packets to a protocol other than SNAP for transmission to the server device 20. For example, the gateway 16 may collect the sensor data received from each of the sensor modules 10 and process and/or re-format such data into a batch for transmission to the server device 20. In some embodiments, the gateway 16 may transmit the resulting sensor data generally in real time. For example, as soon as the data packets are received, the gateway 16 may process and/or re-format the sensor data and immediately, in real-time transmit such data, over the wide network 22, to the server device 20. Alternatively, the gateway 16 may be configured to transmit sensor data to the server device 20 periodically (e.g., once per minute, once per hour, once per day, etc.), or in various other timing arrangements. In some embodiments, the gateway 16 may be configured to store the sensor data for a period of time. For example, if the gateway 16 becomes disconnected from the wide network 22, the gateway 16 may store the sensor data until connection to the wide network 22 has been restored. Finally, in some embodiments, the sensor data may be encrypted by the gateway 16, such that the sensor data can be transmitted to the server device 20 in an encrypted format.
As discussed earlier, in some preferred embodiments, the wide network 22 may be a wide area network (WAN), such as the Internet or other cloud-based network. The communications network 22 may wired or wireless, and may include one or more servers, routers, switches, wireless receivers and transmitters, and the like, as well as electrically conductive cables or optical cables. Furthermore, the wide network 22 may include cellular or mobile phone networks, as well as landline phone networks, public switched telephone networks, fiber optic networks, or the like.
The server device 20 may include one or more computing devices that provide access to one or more general computing resources, such as Internet services, data transfer services, data storage services, and the like. The server device 20 may also provide access to a database that stores information related to the SM System 14 of the present inventive concept. The database may also store other information and data necessary for the implementation of the computer program and method of embodiments of the present invention. For example, the sensor data obtained from the gateway 16 may be stored on the server device 20 for further analysis, as will be discussed in more detail below. In general, the server device 20 may include a computer program configured to implement one or more functions and features described herein. Such computer program may be executed on the server device 20 and/or accessed by a user's computing device (e.g., a desktop, a mobile device, etc.), as will be discussed in more detail below.
In general, the server device 20 may include any device, component, or equipment with a processing element and associated memory elements. The processing element may implement operating systems, and may be capable of executing the computer program, which is also generally known as instructions, commands, software code, executables, applications, apps, and the like. The processing element may include processors, microprocessors, microcontrollers, field programmable gate arrays, and the like, or combinations thereof. The memory elements may be capable of storing or retaining the computer program and may also store data, typically binary data, including text, databases, graphics, audio, video, combinations thereof, and the like. The memory elements may also be known as a “computer-readable storage medium” and may include random access memory (RAM), read only memory (ROM), flash drive memory, floppy disks, hard disk drives, optical storage media such as compact discs (CDs or CDROMs), digital video disc (DVD), Blu-Ray™, and the like, or combinations thereof. In addition to these memory elements, the server device 20 may further include file stores comprising a plurality of hard disk drives, network attached storage, or a separate storage network.
In certain embodiments of the present invention, the computer program may be stored on the server device 20 in a manner that permits a user to access the computer program as an electronic resource, such as a mobile “app” or website. For the web-accessible computer program, the user may simply access the computer program on the server device 20 over a general network (e.g., the Internet) with the user's computing device (e.g., a personal computer, a mobile device, etc.). Alternatively, one or more portions of the computer program may be embodied in a stand-alone program, which can be downloaded on a user's computing device. In such embodiments of the present invention, at least a portion of the computer program may be an “application,” such as an “app” for the user's computing device. After the computer program has been downloaded, the program can be installed on the user's computing device in an executable format. As such, the stand-alone computer program or the web-accessible program provides users with access to the electronic resource from which the users can interact with various embodiments of the present invention, as discussed in more detail below.
In more detail, the electronic resource, as implemented by the computer program running on the server and/or on the user's computing device, permits a user to create a user account. The user account may be associated with a user name and password, which permits the user to access the user account. The user account may be associated with an inventory of one or more sensor modules 10, one or more gateways 16, and/or one or more pieces of equipment (e.g., the equipment to which the sensor modules 10 are connected). For example, the user account may be associated with the three sensor modules 10 and the gateway 16 that form part of the SM System 14 shown in
In view of the above, the electronic resource permits the user to view relevant information for each item in the inventory accessible by the user. For each of the sensor modules 10 associated with the user's user account, the user can access, monitor, and/or analyze the aggregated sensor data for those sensor modules, with such sensor data being aggregated and stored on the database or other memory elements associated with the server device 20 (upon transmission of such sensor data from the gateway 16 over the wide network 22).
In some embodiments, the electronic resource will permit the user to visualize the sensor data for the one or more sensor modules via one or more dashboards or graphical user interfaces (GUIs), which the computer program may be configured to generate on an electronic display of the user's computing device. For example,
In more detail, a first exemplary graph (i.e., the top graph in GUI 100) presents a compilation of the sensor data over time for the given sensor module 10. In more detail, the first exemplary graph shows vibration data over time. Such vibration data may be shown in units of standard gravity “g,” with such vibration data having been obtained from the vibration sensing element 58 of the sensor module 10. Alternatively, or in addition, the vibration data may be shown in units of “inches per second.” with such vibration data having been obtained from the vibration sensing element 58 of the sensor module. In addition, the first exemplary graph shows temperature data over time. Such temperature data may be obtained by the internal temperature sensor and/or the external temperature sensor of the temperature sensing element 56 of the sensor module 10. It should be understood that the sensor module will generally be mounted to a piece of equipment (e.g., the motor 12 of
In addition to the first exemplary graph, which shows a compilation of sensor data over time, the GUI 100 is configured to present the user with a particular subset of the sensor data over time for the given sensor module 10. For example, a second exemplary graph (i.e., the bottom graph in GUI 200) shows vibration data over time, with such vibration data being shown in units of standard gravity “g.” However, a user can select to show any individual type of sensor data within the second exemplary graph.
In addition to the graphs, which display sensor data over time, the GUI 100 may present the instantaneous values of the sensor data for the given sensor module 10. For instance, as show in the upper right-hand corner of the GUI 100, the instantaneous values for the temperature data (both internal temperature and external temperature) for the given sensor module 10 may be shown. The instantaneous battery data, in the form of voltage, for the sensor module's 10 battery 70 may also be shown. In further embodiments, the instantaneous vibration data for the given sensor module 10 may be shown.
As noted previously, the sensor modules 10 may be configured to obtain sensor data at a pre-selected measurement interval. Embodiments of the present invention provide for the user to select such measurement intervals via the electronic resource present by the computer program of the present invention. For example, via the GUI 100 (or another GUI) presented by the electronic resource, the user can select the appropriate measurement interval for each of the one or more sensor modules 10 associated with the user's user account. In some embodiments, the user can select different intervals for each of the sensor modules 10 under the user's control. Furthermore, embodiments may permit the user to select a different measurement interval for each of the different types of sensor data. For example, user may specify that the measurement interval for vibration data and temperature data for a given sensor module 10 is once per minute, while the measurement interval for the battery data for the given sensor module 10 is once per month. Upon establishing the appropriate measurement interval, the server device 20 may send such instructions to the appropriate sensor module 10 via communication with the gateway 16 (over the wide network 22). The gateway 16 can then provide such instructions directly to the appropriate sensor module 10 via the local network 18, such that the sensor module 10 can program its measurement intervals as requested by the user.
The electronic resource may further permit the user to establish alerts for each of the sensor modules 10 associated with the user's user account. Such alerts may provide a notification to the user if any of the sensor data associated with the sensor modules 10 indicates that the sensor module 10 is generating sensor data indicative of an error, a malfunction, and/or a failure. As has been described in more detail above, the sensor modules 10 may each be connected with a piece of equipment, such as motor 12 illustrated in
For instance, the user may create a first alert for a sensor module 10, with the first alert associated with an alert rule that specifies that the first alert is activated if the sensor module 10 experiences a vibration (as indicated by the vibration data) that exceeds a maximum value. The vibration data exceeding the maximum value may be indicative of the piece of equipment to which the sensor module 10 is attached experiencing a mechanical problem or failure. Thus, if the vibration data exceeds the maximum value, then the first alert is activated. Similarly, the user may establish a second alert for the sensor module 10, with the second alert associated with an alert rule that specifies that the second alert is activated if the if the sensor module 10 experiences a temperature (as indicated by the temperature data) that exceeds a maximum value. The temperature data exceeding the maximum value may be indicative of the piece of equipment to which the sensor module 10 is attached experiencing a mechanical problem or failure. As noted previously, each sensor module 10 may include both an internal temperature sensor and an external temperature sensor. The internal temperature sensor may be indicative of the surface temperature of the piece of equipment (e.g., the motor 12) to which the sensor module 10 is attached, while the external temperature sensor may be indicative of a temperature external to the piece of equipment. For example, the external temperature sensor may be secured to a piece of machinery that is being powered by the piece of equipment to which the sensor module 10 is attached. Thus, the temperature data exceeding the maximum value may be indicative of either the piece of equipment failing, or the piece of machinery being powered by the piece of equipment failing. Furthermore, an alert may be created for vibration data falling below a minimum value and/or for temperature data following below a minimum value. Similarly, an alert may be created for battery data falling below a minimum value, which may indicative of the battery 70 for the sensor module 10 requiring replacement or re-charging.
Upon any of the alerts being activated (e.g., by sensor data exceeding the established maximum or minimum values), embodiments may provide an indication of such alert to the user. Such an indication may be in the form of a visible alert displayed on a GUI generated by the electronic resource. Alternatively, or in addition, an audible alert may also be generated by the electronic resource and emitted by the user's computing device. In further alternatives, alert messages may be generated and sent to the user via email or SMS messaging.
In view of the above, embodiments of the present invention provide for sensor data associated with sensor modules 10 to be visualized and analyzed in real time. Based on analysis of such real-time sensor data, as may be displayed via the GUI 100 and/or as may be used as the basis to generate alerts, embodiments of the present invention provide for users to quickly determine the health of equipment to which the sensor modules 10 are connected. For example, if a user receives an alert that a piece of equipment is on the verge of failing due to a mechanical issue (e.g., as may be indicated by sensor data exceeding or falling below an maximum or minimum values), the user may be able to fix the mechanical issue before such failing occurs. Furthermore, by analyzing the real-time or historical sensor data, users can predict and/or identify maintenance issues that may be outside normal maintenance schedules. Thus, embodiments can aid in reducing downtime of equipment and can minimize any costs associated with such downtime.
Finally, in addition to presenting real-time or historical sensor module 10 sensor data via GUI's, embodiments provide for sensor data to be compiled into various reports for downloading and/or further analysis. Such reports may include data for one or more sensor modules 10, one or more groups of sensor modules 10, one or more gateways 16, one or more pieces of equipment (e.g., to which the sensor modules 10 are connected), one or more locations (e.g., where the sensor modules 10, the gateways 16, and/or the pieces of equipment are located), and/or one or more events (e.g., reports based on historical alerts). For example, all of the historical sensor data for each of the sensor modules 10 associated with the user's user account may be stored in the database of the server device 20 and available for download onto the user's computing device for further analysis. Such reports may be used for data analytics to generate equipment maintenance schedules, to proactively identify future equipment failure issues, and/or to identify patterns in the life of equipment.
Although the invention has been described with reference to the one or more embodiments illustrated in the figures, it is understood that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. For example, although the above description primarily discussed the sensor modules 10 being used with motors 12, it should be understood that the sensor modules 10 may be used with other types of equipment that experiences vibration and temperature variations. Such other types of equipment may include, for example, manufacturing equipment, pumps, compressors, heat exchangers, engines, turbines, vehicles, etc.
Having thus described one or more embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:
The present non-provisional patent application claims priority to U.S. Provisional Patent Application No. 62/658,412, filed Apr. 16, 2018, and entitled MOTOR SENSOR MODULE, the entire disclosure of which is hereby incorporated by reference into the present non-provisional patent application. This non-provisional patent application is being filed contemporaneously with U.S. Non-Provisional patent application Ser. No. ______, entitled “SENSOR MODULE SYSTEM,” the entire disclosure of which is hereby incorporated by reference into the present non-provisional patent application
Number | Date | Country | |
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62658412 | Apr 2018 | US |