WO2001050099A1 - Reseau diagnostique avec module experts locaux proactifs informatises - Google Patents

Reseau diagnostique avec module experts locaux proactifs informatises Download PDF

Info

Publication number
WO2001050099A1
WO2001050099A1 PCT/US2000/013521 US0013521W WO0150099A1 WO 2001050099 A1 WO2001050099 A1 WO 2001050099A1 US 0013521 W US0013521 W US 0013521W WO 0150099 A1 WO0150099 A1 WO 0150099A1
Authority
WO
WIPO (PCT)
Prior art keywords
local
experts
network
local experts
machine
Prior art date
Application number
PCT/US2000/013521
Other languages
English (en)
Inventor
Alan J. Reid
Dean A. Lofall
Original Assignee
Reid Asset Management Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/477,959 external-priority patent/US6298308B1/en
Application filed by Reid Asset Management Company filed Critical Reid Asset Management Company
Priority to AU50227/00A priority Critical patent/AU5022700A/en
Publication of WO2001050099A1 publication Critical patent/WO2001050099A1/fr

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the network communication
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H1/00—Measuring characteristics of vibrations in solids by using direct conduction to the detector
    • G01H1/003—Measuring characteristics of vibrations in solids by using direct conduction to the detector of rotating machines
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
    • G05B19/4063—Monitoring general control system
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31151—Lan local area network
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31156—Network structure, internet
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31158—Wan wide area network
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/33—Director till display
    • G05B2219/33002—Artificial intelligence AI, expert, knowledge, rule based system KBS
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/33—Director till display
    • G05B2219/33284—Remote diagnostic
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37351—Detect vibration, ultrasound
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37434—Measuring vibration of machine or workpiece or tool
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37435—Vibration of machine
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/80—Management or planning

Definitions

  • the present invention relates generally to predictive maintenance, and more particularly to a diagnostic network and method which employs local experts to automatically monitor, diagnose and take action in connection with different machines included within a system.
  • Machine malfunction can sometimes be detected by a change in the vibration pattern of that machine.
  • engineers rely on more advanced methods of identifying abnormal levels and patterns of vibration in order to determine the condition of a machine. It is now common to measure the level and rate of the vibrations of machines and use this data to determine which machines require servicing. This monitoring technique is called predictive maintenance.
  • vibration data is typically taken and recorded on a scheduled basis during normal use of the machinery.
  • systems available for this purpose. Many of such systems are designed around a pool of portable data collectors. Each individual data collector is designed to be transported to a machine to be tested. Vibration data from the machine is collected, and the vibration data is subsequently uploaded to a host computer. The host computer analyzes the vibration data in order to provide a system operator with complex diagnoses. See, for example, United States Patent Nos. 4,885,707 and 4,612,620;
  • Portable data collectors also have required considerable labor costs in the past. Several man hours are spent visiting different sites and collecting vibration data from the machines at each site. When problems are detected, oftentimes service personnel and/or more experienced data collector operators must be dispatched to the particular site to determine if in fact there are problems. Again, several more man hours can be lost which may otherwise be attributable to operator error in the original collection of data.
  • the present invention provides an entirely new approach to conducting predictive maintenance.
  • the present invention provides a system in which localized experts are provided at various machine sites.
  • the localized experts are automated data collector/analyzers which are configured to acquire and analyze vibration data substantially continuously from one or more machines located at the site.
  • the vibration data is analyzed in real-time and the condition of the machines may be ascertained without reliance on portable data collectors and/or analysis by a system host computer.
  • one or more local experts are provided at a given site (e.g., building, ship, boiler room, power station, etc.). Each local expert is computer-driven and is configured to receive vibration data from up to thirty-two different machines located at the site.
  • the local expert includes an expert system and database which allows the local expert to analyze the vibration data locally for each particular machine to detect incipient failure, diagnose wear, etc.
  • Each local expert includes an interface which is linked to a system network such as a local-area-network (LAN) or wide-area-network (WAN). Furthermore, each local expert may communicate with a remote location via a dial-up network, the Internet, etc. The diagnoses performed by each local expert can be used to alert appropriate personnel of impending failure, wear (such as bearing wear), necessary maintenance, etc.
  • the system enables a local expert to initiate electronic mail (email) messages and/or electronic pages to appropriate personnel indicating a machine failure or impending failure, a need for maintenance, etc.
  • One or more local experts typically will be sufficient to perform predictive maintenance for an entire site (e.g., an entire building) having several different machines.
  • the database within each local expert contains information specific to the machines connected thereto, as well as information relating to machines of the same type.
  • An expert system within each local expert draws on such information as part of a rules database and/or knowledge database also included therein. Based on such information, the local expert ascertains which machines are operating normally, or are experiencing minor, moderate or severe problems. Depending on the severity of any problems identified by the local expert as well as other possible factors, the local experts are configured to contact the appropriate personnel by email, pages, causing a network event (e.g., setting a flag), etc.
  • a network event e.g., setting a flag
  • the local experts in the present invention not only collect vibration data, but also analyze the data in order to ascertain the condition of the machine and diagnose specific problems such as thrust bearing wear, coupling misalignment, gear problems, etc.
  • the local experts can therefore not only alert the appropriate personnel of a problem, but also can inform the personnel of the particular cause of the problem.
  • the local experts can recommend action needed to be taken.
  • the local experts may identify which bearings need to be replaced on a machine, the specific part numbers of the bearings, and may provide instructions for enabling a maintenance engineer to make any necessary repairs.
  • a person is notified that there is a problem with a particular machine, that person is also notified in many instances of the particular cause of the problem and the maintenance needed to be performed.
  • each local expert in accordance with the present invention is an optional connection to a central monitoring location via the dial-up network or Internet, for example.
  • the central monitoring location may be equipped to do special analysis and/or offer user support.
  • Each local expert is designed to be able to replicate its data within its database into a central monitoring location database. Such replication preferably is carried out automatically by the local expert such that the data is available for review at the central monitoring location substantially as soon as a problem is detected.
  • the local expert is configured to permit the central monitoring location or another location on a local or remote network to control the local expert via the dial-up network or Internet connection. Consequently, the central monitoring location or other location can control the local expert from a remote location to perform special testing and analysis in real time. This enables someone at the central monitoring location or elsewhere to look effectively "under the hood" of the particular machines within the network without necessitating sending personnel directly to the site.
  • a method for invoking condition monitoring among a plurality of machines comprising establishing a network of automated local experts at generally fixed locations and interconnected by at least one network connection, configuring each of the local experts to receive vibration data from at least one of the plurality of machines which is located in relative physical proximity thereto and configuring each of the local experts to analyze the received vibration data and to diagnose a condition of the machine providing the received vibration data based on the received vibration, and configuring each of the local experts to transmit diagnostic information relating to the condition of the respective machines via the at least one network connection.
  • FIG. 1 is a system view illustrating a diagnostic network with an automated local expert in accordance with the present invention
  • Fig. 2 is a system view illustrating a diagnostic network including a plurality of local experts in accordance with the present invention
  • Fig. 3 is a block diagram of a local expert in accordance with the present invention
  • Fig. 4 is a flowchart suitable for programming the operation of the local experts in accordance with the present invention.
  • Fig. 5 is a block diagram illustrating in more detail the expert analyzer and maintenance manager in accordance with the present invention.
  • a diagnostic network in accordance with the present invention is generally designated 10.
  • the network 10 is focused around a particular site or sites (represented by phantom line 12).
  • the site 12 may be an office building, manufacturing facility, power plant, etc., or basically any location(s) having one or more machines which are to be monitored for predictive maintenance. Such machines may be engines, turbines, compressors, generators, motors, or any other type of machine for which predictive maintenance is useful.
  • the site 12, as exemplified in Fig. 1 includes a plurality of machines 14.
  • the machines 14 may each be the same kind of machine or different machines as will be appreciated.
  • the network 10 further includes at least one local expert 16 coupled to the machines 14 for receiving predictive maintenance information such as vibration data.
  • each local expert 16 in the exemplary embodiment is a computer-driven data collector and analyzer.
  • the local expert 16 receives vibration data from each of the machines 14 or a subset thereof.
  • the local expert 16 includes an expert system for analyzing the vibration data in relation to a rules database and/or knowledge database in order to evaluate the condition of the respective machines 14.
  • the local expert 16 includes a database which stores information on the particular machines 14 from which it receives vibration data as well as a library of data on machines of the same type.
  • the expert system may include a neural network, fuzzy logic, or other adaptive and/or predictive analyzers.
  • the local expert 16 analyzes the vibration data and diagnoses the condition of the machines 14.
  • the local expert 16 may diagnose particular bearing wear on a given machine 14.
  • the network 10 can be distinguished over conventional on-line systems in that the local expert 16 is continuously able to collect vibration data as well as configured to analyze the data to provide diagnostic information and intelligently notify the appropriate personnel as is discussed more fully below.
  • each machine 14 includes one or more sensors 18 (e.g., accelerometers) for providing a respective vibration data signal to the local expert 16.
  • each local expert 16 has a 32 channel input and is thus capable of receiving vibration data signals from up to 32 different sensors 18.
  • each local expert 16 could be designed to have some other number of channels without departing from the scope of the invention.
  • Each machine 14 may have one or more sensors 18 mounted thereon. The output from each sensor 18 is coupled to the local expert 16 via a hardwired cable, for example. Alternatively, the output of each sensor 18 may be transmitted to the local expert 16 via an optical cable link, or wirelessly via an infrared link, radio link, etc.
  • the local expert 16 may be mounted on a wall or some other location within the site 12, away from the vibration, dirt, debris, etc. which may be found near the machines 14. At the same time, a single local expert 16 can be used to monitor up to 32 different machines (or some other number).
  • Fig. 1 illustrates how the network 10 further includes a system backbone 20 (such as an Ethernet or Token Ring bus) to which each local expert 16 is coupled.
  • the system backbone 20 typically will be part of a local area network (LAN) or wide area network (WAN) found at the site 12 which provides for everyday communications. Nevertheless, the system backbone 20 may be part of a dedicated network for use in accordance with the present invention.
  • LAN local area network
  • WAN wide area network
  • the network 10 includes devices coupled to the system backbone 20 such as one or more web-based clients 22 for requesting information from the local experts 16 in a web-based format (e.g., html files). Such information includes information relating to the collected vibration data for a given machine 14, diagnostic information provided by the local experts 16, etc.
  • One or more "object linking embedding (OLE) process control" (commonly known as
  • OPC OPC
  • OPC mimic display client(s) 24 is provided on the backbone 20 and permits mimicking of the OPC control of the local expert(s) 16 anywhere within the network.
  • An email server 26 is also coupled to the backbone 20 and functions to control the routing of email messages provided by the local experts 16 within the network site 12 to their
  • One or more email clients are coupled to the system backbone 20 (either directly or indirectly) and represents the addresses of personnel identified as being appropriate to receive emails from the local experts 16 regarding the condition of a machine 14.
  • One or more control panel OPC interfaces 28 are also provided on the system backbone 20 for allowing personnel located remote from the local experts 16 to control the local experts and/or other conditions involving the machines 14, as well as view data collected and/or analyzed by the local experts 16 as is discussed in more detail below.
  • Each local expert 16 has a pager server on board for generating and sending pager messages.
  • the pager messages are used to send alerts as to machine condition as determined by the local experts 16.
  • the pager client 29 shown in Fig. 1 may be a local pager facility for transmitting pages to the appropriate individual pagers within the site 12, or a link to a standard commercial paging facility which transmits pages over a wide region.
  • the local expert(s) 16 are each able to communicate with such devices coupled to the system backbone 20 by employing known network communication protocols as noted above.
  • the backbone 20 may be a hardwired medium or wireless medium such as infrared, RF, etc., as will be appreciated.
  • connections with other networks or devices within the network system 10 may include hardwired links, wireless links, etc. Communications may take place via modem, radio transmission, satellite communications, etc., as will be appreciated.
  • a local expert 16 which diagnoses a problem with one of the machines 14 it is monitoring is designed to notify the appropriate personnel via email, pager, and/or causing a network event, for example.
  • the local expert 16 diagnoses a problem it is configured to generate an email or page, for example, which is provided to the email server 26/pager client 29 via the backbone 20.
  • the email server 26 in turn routes the email and/or pager message to the addressee.
  • the content of the email is generated by the local expert 16, and includes the diagnoses ascertained by the local expert 16.
  • an email and/or pager text message indicating "Machine ID XYZ has minor/advanced/extreme bearing fault" is generated by the local expert 16 based on its analysis.
  • the local expert 16 has an address book stored therein identifying the email/pager addresses of the appropriate personnel to be notified in the event of problems with a given machine 14.
  • Such personnel may be operations and/or maintenance personnel for the particular type of machine involved. In this manner, the maintenance personnel are not required to periodically visit each machine 14 to evaluate its condition. Operations personnel are thereby notified as to whether machinery lineup changes, configuration changes, etc., are necessary. Thus, the operations and maintenance personnel can attend to other matters
  • the diagnoses performed by the local experts 16 are actual diagnoses where the local experts 16 diagnose and provide diagnostic information relating to the condition of the respective machines. Examples of such diagnoses include both the condition and level of severity. As specific examples, a local expert 16 may identify a "moderate decanter drive and looseness", “moderate decanter free end looseness”, “moderate decanter drive end bearing wear”, etc. Additional examples may be found in the Expert Alert software discussed below. Such diagnoses inform the receiver of the diagnostic information of the specific machine condition, not simply a general failure probability as in conventional systems.
  • the pager messages generated by the local experts 16 are relatively brief messages (e.g., on the other order of 100-200 characters). Such messages identify the specific machine 14 and diagnosed problem.
  • Email messages include additional information such as a summary of the data analysis which resulted in the local expert 16 diagnosing a problem with the machine 14, recommended maintenance information, etc.
  • Each local expert 16 may also be connected to another network outside of the local site network via a telephone line connection or the like.
  • each local expert 16 may include a modem 30 which serves to link the local expert 16 to an external network such as a Windows Dial Up Network (DUN) or Internet Virtual Private Network (VPN).
  • DUN Windows Dial Up Network
  • VPN Internet Virtual Private Network
  • each local expert 16 is coupled via a modem 30 to a central monitoring location 34.
  • the central monitoring location 34 includes analysis software similar to that found in each local expert 16.
  • the central monitoring location 34 may include an even more extensive database from which its expert system may draw on.
  • the central monitoring location 34 is part of an external network which is also configured to receive email and/or pager messages from the local experts in the same manner discussed above.
  • an email message or pager message which is generated by a local expert 16 can be delivered via the modem 30 and telephone line to a remote network including the central monitoring location 34, for example.
  • the central monitoring location 34 is configured to control the local experts 16 via the DUN or VPN, for example, and is thus capable of performing real time analysis of data collected by a given local expert 16.
  • a local expert 16 can replicate the vibration data obtained from one or more of the machines 14 into the database of the central monitoring location 34. More experienced personnel at the central monitoring location 34 can then review the vibration data.
  • OPC control the central monitoring location 34 may control the operation of the local expert 16 to run custom testing.
  • other remote interfaces different from OPC may be used without departing from the scope of the invention.
  • Human experts at the central monitoring location 34 can therefore view the data obtained by the local experts 16 from a particular machine, cause the local expert 16 to do additional testing, etc. These human experts can then replicate the data back to the local experts 16 and attach any comments or recommendations they have based on their analysis.
  • the local experts 16 are configured to display such data and comments to facilitate the actions of on-site personnel.
  • One advantage of the present invention is that vibration data can be collected, analyzed and, in the case of a problem, people can be notified of the problem, repairs may be suggested, and the central monitoring location can be provided with relevant vibration data all in advance of human intervention.
  • the present invention allows corrective action to begin even before a human may be aware that a given machine 14 may have a problem.
  • Fig. 2 illustrates an embodiment wherein several local experts 16 are located at the site 12.
  • Each local expert 16 is coupled to the system backbone 20 and is configured to communicate with the respective devices 22, 24, 26, 28 and 29 in the same manner described above.
  • each local expert 16 communicates via a modem 30 (shared or individual) to the external DUN or VPN.
  • Fig. 3 is a block diagram illustrating an exemplary embodiment of a local expert 16.
  • the local expert 16 includes a central processing unit (CPU) 50 which is programmed to carry out the various functions described herein using conventional programming techniques.
  • the CPU 50 may be any suitable processor such as the commercially available Intel Pentium or AMD K6 microprocessors.
  • the local expert further includes a memory 52 comprising volatile and non-volatile memory serving as working memory as well as storing system software for causing the local expert to perform the functions described herein. Since such functions may be carried out using code written in any of a number of different programming languages using conventional techniques, details regarding the specific code have been omitted herein for sake of brevity.
  • a display 54 serves to display information to a user, such as providing a visual status display indicating the operation of the local expert 16.
  • a suitable network interface 56 is included for permitting the local expert to communicate with other devices on the system backbone 20.
  • the modem 30 is included which allows the local expert 16 to communicate with other devices on the external network (e.g., DUN or VPN).
  • a user interface 58 such as a keypad or touch sensitive screen is optionally provided to allow a user to input information locally at the site 12.
  • a control interface 60 is provided which allows the local expert 16 to receive control system inputs, data, etc. locally at the site 12.
  • a power supply 62 provides suitable operating power to the local expert 16.
  • the power supply 62 may serve to provide power based on a standard 120 volt system, for example. In the event the local expert 16 is located at a remote site 12, the power supply 62 may be designed to provide operating power based on battery power, solar power, etc.
  • the local expert includes a multiplexer 70 which receives as an input the signals from each of the sensors 18 from the various machines 14 corresponding thereto. Under the control of the CPU 50, the multiplexer 70 determines from which machine 14 and sensor 18 vibration data is received at a given period in time. The output of the multiplexer 70 is provided to a data acquisition card 72 which conditions, filters and digitizes the data from each machine 14. The vibration data from each machine 14 is then stored in a database memory 74 included in the local expert 16.
  • the database memory 74 is a large, non- volatile memory such as a conventional hard disk storage medium found in personal computers.
  • the database 74 In addition to storing vibration data obtained from the machines 14, the database 74 also stores information relating to other machines, trending information, a rules database and/or knowledge database, process and performance information, etc., which are used by the local expert 16 for analyzing the vibration data and making diagnoses. More particularly, the local expert 16 includes an expert system 76 embodied in software which is stored in the memory 52 and/or the database 74.
  • the expert system 76 includes a data collector module 78 which is designed to oversee the collection of vibration data from each of the machines 14 to which the local expert 16 is connected.
  • the local expert 16 further includes an expert analyzer module 80 designed to analyze the vibration data collected from each of the machines 14 connected thereto in order to diagnose the condition of the machines 14.
  • the data collector module 78 and the expert analyzer module 80 employ the same features and functions which are found in the DCX Portable Data Collector/Analyzer commercially available from Predict/DLI, Bainbridge, Washington, USA. Details regarding the expert analysis and the functions thereof can also be found in relation to the Expert Alert software available in the DCX Portable Data Collector/Analyzer from Predict/DLI.
  • the expert system 76 further includes a communications manager 82 which includes tables listing the network addresses, email addresses, pager addresses, etc. of the appropriate personnel to be notified in the event of a problem with any particular machine 14. The contents of such tables are provided to the local expert 16 as part of the system initialization.
  • the communications manager 82 also keeps track of the appropriate communications protocol to be used when communicating with the intended party. For example, the communications manager 82 keeps track of whether a message relating to the condition of a machine is to be communicated as an email, a page, standard network communication, or the like. In addition, the communications manager 82 takes care of packaging the communications from the local expert 16 into the appropriate format.
  • the communications manager 82 embodies within itself software executed by the CPU 50 which serves as a pager server and email client as desired for carrying out the communications referred to herein.
  • the expert system 76 also includes a maintenance manager 84 for facilitating maintenance of a given machine 14.
  • the maintenance manager 84 includes in memory details relating to the maintenance and repair of the particular machines 14 coupled to the local expert 16. Such details may be stored in the local expert 16 as part of the system initialization.
  • the maintenance manager 84 may include a list of parts which are subject to wear in connection with each machine 14. Such parts may include bearings, sleeves, rotors, etc.
  • the maintenance manager 84 can look to a look-up table in memory within the local expert 16 and identify the particular part (e.g., bearing size, part number, etc.).
  • the maintenance manager 84 includes within a look-up table in memory details regarding the repair of different types of failures in the machines 14. For example, the maintenance manager 84 draws from such information and automatically provides details to a user on how to replace a bearing which is worn or has failed via the display 54. Such information may include drawings, instructions, etc. which are shown on the display 54. In addition, or in the alternative, such information is attached to an email message notifying the appropriate personnel of the problem with the machine 14.
  • repair information will depend, of course, on the diagnosed problem and the particular machine 14. Nevertheless, it is particularly useful for the local expert 16 to be able to provide maintenance instruction locally and throughout the network based on the diagnosed problem.
  • the expert system 76 also includes a data replication manager 86 used to duplicate data obtained by the local expert 16 and provide such data to another device such as the central monitoring location 34.
  • the data replication manager 86 is designed to replicate data obtained from a machine 14 in the event a problem is diagnosed in the machine 14 by the expert analyzer 80. Upon diagnosing a problem, depending on the severity the data replication manager 86 initiates a communication link between the local expert 16 and the central
  • 1 1 monitoring location 34 for example, and the vibration data from the machine 14 is copied to the central monitoring location 34 automatically.
  • the replicated data will be available at the central monitoring location 34 almost as soon as a problem is detected. This saves time as someone at the central monitoring location 34 can further analyze the data without waiting for service personnel to visit the site 12 to ascertain the problem and acquire the data.
  • Personnel at the central monitoring location 34 can be evaluating the vibration data locally even as other personnel are being notified of the problem via email, pager, etc. Since the personnel at the central monitoring location 34 will thereby have local access to the replicated data, this also avoids delays which can arise due to slow network communications if the central monitoring location 34 were to access the database of the local expert 16 directly.
  • the expert system 76 further includes an OPC server 88 for allowing OPC control of the local expert 16 via the central monitoring location 34 or other remote controller (e.g., OPC interface 28).
  • OPC control allows the remote device to review data obtained by the local expert 16, as well as control the function thereof.
  • the local expert 16 may be controlled to perform such tests via the DUN, VPN, etc.
  • the local expert 16 also includes a web server 90 responsible for maintaining one or more web-based files within the local expert 16. Such files preferably are maintained with information relating to the analysis of the vibration data for the respective machines. Thus, someone out on the network (either locally or via the DUN or VPN can access the web pages from the local expert 16 and ascertain the condition of the machines 14.
  • Fig. 4 is a flowchart illustrating the general operation of each local expert 16.
  • the local expert 16 collects data from a given machine 14 by virtue of the data collector module 78.
  • the local expert 16 analyzes the collected data using the expert analyzer in step 102.
  • the analysis includes sensitivity to various operating states of the machine 14, e.g., whether under full operation, partial operation, or powered down. Based on such analysis, the condition of the respective machines 14 connected to the local expert 16 can be diagnosed.
  • any problems with the machine are predefined as being either extreme so as to indicate failure or incipient failure, advanced, or minor.
  • the local expert 16 is predefined as being either extreme so as to indicate failure or incipient failure, advanced, or minor.
  • step 107 OPC operation availability is represented as always available for control of the local device 16, review of the data therein, and/or control of the processes associated with the machines 14. For example, if a problem with a machine 14 is detected, OPC control can be used to power down the machine 14 or perform other process control from the remote location.
  • the local expert 16 proceeds based on whether the problem is predefined as extreme, moderate or minor. It will be appreciated that although the exemplary embodiment identifies three general types of problems and responses thereto, there are countless other ways in which operation can be categorized and implemented. If the diagnosed problem is considered indicative of failure or incipient failure as represented in step 108, the communications manager 82 causes a pager message(s) and email(s) to be sent out indicating the particular machine 14 and problem diagnosed by the expert analyzer 76. Such messages are sent to the appropriate personnel responsible for handling such information as represented in steps 110 and 112.
  • step 114 the data replication manager 86 proceeds to replicate automatically the vibration data indicating the problem to the central monitoring location 34 so that such information will be readily available to those desiring to study the data in more detail.
  • the OPC server 88 in step 116 allows for control of the local expert 16 via the DUN or VPN as desired. Further steps such as recommending maintenance via the maintenance manager 84 may also be employed.
  • step 118 If the problem diagnosed in steps 102 and 104 is considered advanced as represented in step 118, it may be desired that the local expert 16 forgo sending a pager message and instead simply send an email message alerting the appropriate personnel of the particular problem as represented in step 120. Thereafter, the local expert 16 proceeds to replicate the data in step 122 in the same manner described above in relation to step 114.
  • step 124 the maintenance manager 84 generates information regarding repair of the diagnosed problem. For example, the maintenance manager 84 looks up information stored in memory in the local expert 16 relating to the failed part, etc. as diagnosed by the expert analyzer 80. Such information is then provided to the appropriate personnel via the communications manager 82.
  • step 126 the maintenance manager 84 looks up repair information stored in the local expert 16 and displays the information via the display 54, for example. As represented in step 107, OPC control remains available in the background.
  • the communications manager 82 in step 130 may simply provide an email message to the appropriate personnel as in steps 112 and 120, for example. It will be
  • Fig. 4 illustrates an exemplary manner in which various types of problems can be handled by way of different notices, control, replication of data, etc. Other configurations are well within the intended scope of the present invention.
  • the local expert 16 proceeds to update its database 74 with the information obtained by the analysis as represented in step 132. Process then returns to step 100 where the vibration data for the other machines 14 to which the local expert 16 is connected is collected.
  • Fig. 5 illustrates in more detail the expert analyzer 80 and maintenance manager 84 of the expert system 76.
  • the expert analyzer 80 comprises an analysis engine 150 which draws upon information contained in a knowledge database 152 and a rules database 154.
  • the databases 152 and 154 include information specific to the particular machines 14, as well as machines which are generally the same type.
  • the expert analyzer employs a neural network or fuzzy-based system trained to diagnose machine faults based on vibration data obtained by the local expert 16.
  • the analysis engine 150 may draw from information included in the knowledge database 152 and a rules database 154 to diagnose problems in a given machine 14 based on its vibration data.
  • Such diagnosis is then output to the CPU 50 as well as input to the maintenance manager 84.
  • the maintenance manager 84 receives the diagnosis at looks to information included within its look up tables to provide relevant information to the appropriate personnel. '
  • the maintenance manager 84 includes a parts list 156 which has stored therein the relevant parts for each machine 14 connected to the local expert 16. The maintenance manager 84 uses such information to notify personnel of the particulars involving a part which may have failed or will soon fail as determined by the expert analyzer 80.
  • the maintenance manager 84 further includes repair information 158 which the maintenance manager relies upon for providing repair information relating to a diagnosed problem.
  • the maintenance manager includes maintenance schedules 160 which may be used to enable the local expert 16 to automatically send out reminders via email that a particular machine 14 is in need of routine maintenance.
  • Each of the parts lists 156, repair information 158 and maintenance schedules 160 are handled by a maintenance engine 162 for delivery to the CPU 50 as needed.
  • each of the local experts 16 is configured to transmit periodically a status message to the central monitoring location 34 confirming that the local expert 16 is itself functioning properly. More specifically, local experts 16 are configured to run self-tests to confirm proper operation. If a local expert 16 reports a status problem or fails to report within an expected period, the central monitoring location 34
  • Such status reports from the local experts 16 may be provided via email, for example, or other network communication. Of course, other approaches may also be used for ascertaining the operational status of the local experts 16 without departing from the scope of the invention.
  • the local experts 16 periodically provide machine condition reports to the central monitoring location 34 with respect to the machines 14 being monitored. Thus, even in the event no problems are diagnosed a local expert 16 periodically provides a condition and/or status report for each machine 14 being monitored to the central monitoring location 34. This allows central databases to be created, evaluated, etc. At the same time, each local expert 16 preferably periodically replicates its database to the central monitoring location 34.
  • the periodicity of the status reports, machine condition reports and data replication may be the same or different as desired.
  • the present invention provides a network system and method for conducting predictive maintenance in which localized experts are provided at various machine sites.
  • the localized experts are automated data collector/analyzers which are configured to acquire and analyze vibration data substantially continuously from one or more machines located at the site.
  • the vibration data is analyzed in real-time and the condition of the machines may be ascertained without the reliance on portable data collectors and/or analysis by a system host computer.
  • Local experts at a given site are computer-driven and are configured to receive vibration data from up to thirty-two different machines located at the site.
  • the local expert includes an expert system and database which allows the local expert to analyze the vibration data locally for each particular machine to detect incipient failure, diagnose wear, etc.
  • Each local expert includes an interface which is linked to a system network such as a local-area-network (LAN) or wide-area-network (WAN), and may communicate with a remote location via a dial-up network, the Internet, etc.
  • the diagnoses performed by each local expert can be used to alert appropriate personnel of impending failure, wear (such as bearing wear), necessary maintenance, etc.
  • the system enables a local expert to initiate electronic mail (email) messages and/or electronic pages to appropriate personnel of a machine failure or impending failure, a need for maintenance, etc.
  • one or more information servers may reside at different locations on the network 10 or elsewhere via a WAN connection.
  • the information servers are configured to receive the diagnostic information from the local experts 16.
  • local experts 16 may be configured to provide the diagnostic information to the information servers automatically, or upon receiving a prompt from the information servers via the network.
  • the information servers in turn are configured to decide if and when to send a message, dial a modem, update a remote web site, or otherwise pass the diagnostic information from the local experts 16 on to another network location.
  • the present invention is no longer dependent on a system host computer or portable data collectors.
  • the present invention is capable of performing its own complex analyses of vibration data and can operate without a system host.
  • the present invention eliminates the need for extensive maintenance personnel resident at each site.
  • the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of the specification.
  • the various connections between components can be carried out using wireless techniques such as optical, infrared or RF without departing from the scope of the invention.
  • the local experts 16 described herein may be programmed to perform trending with respect to the collected data. Such trending can be incorporated into the expert analyzer.
  • predictive maintenance data other than vibration data can be utilized without departing from the scope of the invention.
  • lubricant analysis or other means for evaluating the condition of the machines can be incorporated into the local experts.
  • the preferred embodiment includes the local experts mounted separate and apart from the respective machines, it will be appreciated that a local expert could be mounted to each machine.
  • the local expert can be an aftermarket device which is mounted to the machine, or a piece of original equipment which is provided with the machine itself.
  • the present invention includes all such equivalents and modifications.

Landscapes

  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Automation & Control Theory (AREA)
  • Human Computer Interaction (AREA)
  • General Engineering & Computer Science (AREA)
  • Quality & Reliability (AREA)
  • Testing And Monitoring For Control Systems (AREA)

Abstract

La présente invention concerne un procédé permettant d'appeler la surveillance d'état parmi une pluralité de machines, qui consiste à établir un réseau de modules experts locaux informatisés situés à des localisations généralement fixes et interconnectés par au moins une connexion de réseau, à configurer chacun des modules experts locaux de façon qu'ils reçoivent des données de vibration d'au moins une des machines de la pluralité susmentionnée située dans une proximité physique relative de leur localisation, à configurer chacun des modules experts locaux de façon qu'ils analysent les données de vibration reçues et qu'ils établissent à partir de ces dernières un diagnostic de l'état de la machine ayant fourni ces données de vibrations, et à configurer chacun de ces modules experts locaux de façon qu'ils transmettent des informations de diagnostic relatives à l'état des machines respectives via la ou les connexions de réseau.
PCT/US2000/013521 2000-01-05 2000-05-17 Reseau diagnostique avec module experts locaux proactifs informatises WO2001050099A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU50227/00A AU5022700A (en) 2000-01-05 2000-05-17 Diagnostic network with automated proactive local experts

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/477,959 US6298308B1 (en) 1999-05-20 2000-01-05 Diagnostic network with automated proactive local experts
US09/477,959 2000-01-05

Publications (1)

Publication Number Publication Date
WO2001050099A1 true WO2001050099A1 (fr) 2001-07-12

Family

ID=23898006

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/013521 WO2001050099A1 (fr) 2000-01-05 2000-05-17 Reseau diagnostique avec module experts locaux proactifs informatises

Country Status (2)

Country Link
AU (1) AU5022700A (fr)
WO (1) WO2001050099A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1162524A2 (fr) * 2000-06-06 2001-12-12 Mori Seiki Co., Ltd. Système pour l'entretien d'une machine-outil
WO2005016552A3 (fr) * 2003-08-12 2005-07-28 Nordson Corp Systeme de commande convivial destine a un equipement de revetement
WO2006028294A1 (fr) * 2004-09-09 2006-03-16 Amada Company, Limited Systeme et procede d'assistance clientele
WO2007077082A1 (fr) * 2005-12-29 2007-07-12 Endress+Hauser Process Solutions Ag Procede pour entretenir une installation technique automatisee
ES2294959A1 (es) * 2003-11-14 2008-04-01 Gamesa Eolica, S.A. Sociedad Unipersonal Equipo de monitorizacion y proceso para aerogeneradores y sistema de mantenimiento predictivo para parques eolicos.
WO2008087191A1 (fr) * 2007-01-19 2008-07-24 Abb Research Ltd Supervision de réseau avec des systèmes de commande
EP2042956A3 (fr) * 2007-09-26 2010-07-07 Robert Bosch GmbH Interface entre un système de gestion de la fabrication et un système d'automatisation
IT201800003532A1 (it) * 2018-03-14 2019-09-14 Massaro Libero Angelo Macchina curvatubi ultracompatta

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5414494A (en) * 1993-12-06 1995-05-09 Xerox Corporation Automatic call to selected remote operators in response to predetermined machine conditions
US5710723A (en) * 1995-04-05 1998-01-20 Dayton T. Brown Method and apparatus for performing pre-emptive maintenance on operating equipment
WO1998039718A1 (fr) * 1997-03-04 1998-09-11 Emerson Electric Co. Systeme de diagnostic distribue
US5963884A (en) * 1996-09-23 1999-10-05 Machine Xpert, Llc Predictive maintenance system
WO1999060351A1 (fr) * 1998-05-20 1999-11-25 Reid Asset Management Company Collecteur et analyseur de donnees de vibrations de diagnostic

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5414494A (en) * 1993-12-06 1995-05-09 Xerox Corporation Automatic call to selected remote operators in response to predetermined machine conditions
US5710723A (en) * 1995-04-05 1998-01-20 Dayton T. Brown Method and apparatus for performing pre-emptive maintenance on operating equipment
US5963884A (en) * 1996-09-23 1999-10-05 Machine Xpert, Llc Predictive maintenance system
WO1998039718A1 (fr) * 1997-03-04 1998-09-11 Emerson Electric Co. Systeme de diagnostic distribue
WO1999060351A1 (fr) * 1998-05-20 1999-11-25 Reid Asset Management Company Collecteur et analyseur de donnees de vibrations de diagnostic

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1162524A2 (fr) * 2000-06-06 2001-12-12 Mori Seiki Co., Ltd. Système pour l'entretien d'une machine-outil
EP1162524A3 (fr) * 2000-06-06 2004-04-07 Mori Seiki Co., Ltd. Système pour l'entretien d'une machine-outil
WO2005016552A3 (fr) * 2003-08-12 2005-07-28 Nordson Corp Systeme de commande convivial destine a un equipement de revetement
ES2294959A1 (es) * 2003-11-14 2008-04-01 Gamesa Eolica, S.A. Sociedad Unipersonal Equipo de monitorizacion y proceso para aerogeneradores y sistema de mantenimiento predictivo para parques eolicos.
WO2006028294A1 (fr) * 2004-09-09 2006-03-16 Amada Company, Limited Systeme et procede d'assistance clientele
US7505873B2 (en) 2004-09-09 2009-03-17 Amada Company, Limited Customer support system and method of customer support
US7561988B2 (en) 2004-09-09 2009-07-14 Amada Company, Limited Customer support system
WO2007077082A1 (fr) * 2005-12-29 2007-07-12 Endress+Hauser Process Solutions Ag Procede pour entretenir une installation technique automatisee
WO2008087191A1 (fr) * 2007-01-19 2008-07-24 Abb Research Ltd Supervision de réseau avec des systèmes de commande
US8639799B2 (en) 2007-01-19 2014-01-28 Abb Research Ltd. Network supervision with control systems
EP2042956A3 (fr) * 2007-09-26 2010-07-07 Robert Bosch GmbH Interface entre un système de gestion de la fabrication et un système d'automatisation
IT201800003532A1 (it) * 2018-03-14 2019-09-14 Massaro Libero Angelo Macchina curvatubi ultracompatta

Also Published As

Publication number Publication date
AU5022700A (en) 2001-07-16

Similar Documents

Publication Publication Date Title
US6298308B1 (en) Diagnostic network with automated proactive local experts
JP3612472B2 (ja) 遠隔監視診断システム、及び遠隔監視診断方法
US6591296B1 (en) Remote notification of machine diagnostic information utilizing a unique email address identifying the sensor, the associated machine, and the associated machine condition
US6983207B2 (en) Machine component monitoring, diagnosing and selling system
US6370455B1 (en) Method and apparatus for networked wheel alignment communications and service
US5061916A (en) Event driven remote graphical reporting of building automation system parameters
CN102890504B (zh) 集成到过程控制/安全系统中的在线装置检测块
JP4545145B2 (ja) プロセスプラント通知の配信
EP1111550B1 (fr) Méthode et système pour surveiller le fonctionnement d'une machine isolée
EP1538503A1 (fr) Procédé d'évaluation des événements dans une centrale électrique répartie et procédé pour déterminer un plan de réduction
US20030046382A1 (en) System and method for scalable multi-level remote diagnosis and predictive maintenance
JP2000259729A (ja) 作業機械の管理システム
NO342597B1 (no) System for overvåkning og administrering av vedlikehold av utstyrskomponenter
CA2412744A1 (fr) Systeme et procede de gestion d'une entreprise de services
JP2003150237A (ja) 高温部品の遠隔監視システムおよび遠隔監視方法
WO2001050099A1 (fr) Reseau diagnostique avec module experts locaux proactifs informatises
NO320468B1 (no) System for overvakning og administrasjon av vedlikehold av utstyrskomponenter
US8521474B2 (en) Intelligent system diagnostics for bank note processing machines
JP2001084035A (ja) 運転監視システム
EP1419442A2 (fr) Systeme et procede de diagnostic multiniveau echelonnable a distance et maintenance conditionnelle
JP2023183733A (ja) 制御装置、端末装置、管理システム、および管理方法
JPH11102303A (ja) 電子メール連動型診断処理システム
JP2011192201A (ja) リモート保全システムおよびリモート保全方法
Tse et al. Web and virtual instrument based machine remote sensing, monitoring and fault diagnostic system
CN113592179B (zh) 预测性维护方法、系统及存储介质

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AU CA

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE

121 Ep: the epo has been informed by wipo that ep was designated in this application
DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
122 Ep: pct application non-entry in european phase