Systems and methods for analyzing stream-based data for asset operation

Patent metadata

Field	Value
Publication number	US-11221607-B2
Application number	US-201916252851-A
Country	US
Kind code	B2
Filing date	Jan 21, 2019
Priority date	Nov 13, 2018
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

A system includes a first asset disposed at a first location in an industrial system configured to perform one or more operations, a second asset disposed at a second location in the industrial system, and a server device communicatively coupled to the first asset and the second asset. The server device is configured to receive a first set of stream-based data from the first asset, receive a second set of stream-based data from the second asset, identify a first portion of the first set of stream-based data and a second portion of the second set of stream-based data, wherein the first portion and the second portion comprises a same type of data, determine whether the first portion of the first set of stream-based data corresponds to an expected range of values based on the second portion of the second set of stream-based data, and send a command to the first asset to adjust a first set of operations in response to the first portion of the first set of stream-based data not being within the expected range of values.

First claim

The invention claimed is:

1. A system, comprising:
a first asset disposed at a first location in an industrial system configured to perform one or more operations;
a second asset disposed at a second location in the industrial system; and
a server device communicatively coupled to the first asset and the second asset, wherein the server device is configured to:
receive a first set of stream-based data from the first asset;
receive a second set of stream-based data from the second asset;
identify in the first set of stream-based data, a first portion to have a first data type as one of a temperature type, a pressure type, or a flow rate type;
identify in the second set of stream-based data, a second portion to have a second data type, wherein the second data type is same as the first data type, wherein the second data type is identified based at least in part on the values of the second portion of the second set of stream-based data and changes of the values over a time period;
determine whether the first portion of the first set of stream-based data corresponds to an expected range of values based on the second portion of the second set of stream-based data; and
send a command to the first asset to adjust a first set of operations in response to the first portion of the first set of stream-based data not being within the expected range of values.

2. The system of claim 1 , wherein the first portion and the second portion are associated with a type of device coupled to a common hydrocarbon deposit.

3. The system of claim 2 , wherein the type of device comprises a separator device, an electric submersible pump, a valve, or a remote terminal unit.

4. The system of claim 2 , wherein the type of device is determined based on a manufacturer of the first asset and the second asset.

5. The system of claim 1 , wherein the server device is configured to:
monitor a first alarm limit drift with respect to the first portion of the first set of stream-based data; and
adjust a second alarm limit for the second portion of the second set of data based on the first alarm drift.

6. The system of claim 1 , wherein the industrial system comprises a chemical processing system, a food and beverage processing system, a hydrocarbon extraction system, or a mining system.

7. The system of claim 1 , wherein the server device is configured to:
receive sensor data representative of the one or more operations;
determine a state of the industrial system by applying a fuzzy logic algorithm
comprising a relationship between the first portion, the second portion, and the sensor data; and
send an additional command to the first asset or the second asset based on the state.

8. The system of claim 1 , wherein the server device is configured to determine a state associated with the first asset based on fuzzy logic, a first plurality of datasets from the first set of stream-based data, and a second plurality of datasets from the second set of stream-based data.

9. The system of claim 1 , wherein the server device is configured to: recognize that the first portion of the first set of stream-based data does not include metadata;
determine a data type of the first portion; generate new metadata for the first portion; and add the new metadata to the first portion.

10. The system of claim 1 , wherein the server device is configured to:
determine a first state of the first portion;
determine a second state of the second portion;
determine a degree of truth value for each of a plurality of conditions by applying the first state and the second state to one or more fuzzy logic truth tables; and
determine whether each of the degree of truth values for each of the plurality of conditions exceeds a respective condition threshold value.

11. The system of claim 10 , wherein the server device is configured to:
determine that a first condition of the plurality of conditions is correlated with a second condition of the plurality of conditions; and
send a second command to the second asset to adjust a second set of operations.

12. The system of claim 10 , comprising utilizing the one or more fuzzy logic truth tables to recognize drift in the first set of stream-based data or the second set of stream-based data and adjusting a first alarm limit for the first portion of the first set of data or a second alarm limit for the second portion of the second set of data based on the drift.

13. A method, comprising:
receiving a first set of stream-based data from a first asset disposed at a first location in an industrial system configured to perform one or more operations;
receiving a second set of stream-based data from a second asset disposed at a second location in the industrial system;
identifying in the first set of stream-based data, a first portion to have a first data type as one of a temperature type, a pressure type, or a flow rate type;
identifying in the second set of stream-based data, a second portion to have a second data type, wherein the second data type is same as the first data type, wherein the second data type is identified based at least in part on the values of the second portion of the second set of stream-based data and changes of the values over a time period;
determining whether the first portion of the first set of stream-based data corresponds to an expected range of values based on the second portion of the second set of stream-based data; and
sending a command to the first asset to adjust a first set of operations in response to the first portion of the first set of stream-based data not being within the expected range of values.

14. The method of claim 13 , comprising:
monitoring a first alarm limit drift with respect to the first portion of the first set of stream-based data; and
adjusting a second alarm limit for the second portion of the second set of data based on the first alarm drift.

15. The method of claim 13 , comprising:
receiving sensor data representative of the one or more operations;
determining a state of the industrial system by applying a fuzzy logic algorithm comprising a relationship between the first portion, the second portion, and the sensor data; and
sending an additional command to the first asset or the second asset based on the state.

16. The method of claim 13 , comprising recognizing that the first portion of the first set of stream-based data does not include metadata;
determining a data type of the first portion; generating new metadata for the first portion; and adding the new metadata to the first portion.

17. The method of claim 13 , comprising:
determining a first state of the first portion; determining a second state of the second portion;
determining a degree of truth value for each of a plurality of conditions by applying the first state and the second state to one or more fuzzy logic truth tables; and
determining whether each of the degree of truth values for each of the plurality of conditions exceeds a respective condition threshold value.

Assignees

• Rockwell Automation Tech Inc

Inventors

• Gray Edward A
• Weatherhead Norman A
• Mashetty Srikanth G

Classifications

• G05B2219/31449

  Monitor workflow, to optimize business, industrial processes · CPC title

• G05B19/406 Primary

  characterised by monitoring or safety (G05B19/19 takes precedence) · CPC title

• G05B2219/31282

  Data acquisition, BDE MDE · CPC title

• Y02P90/02

  Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] · CPC title

• G05B19/4183 Primary

  characterised by data acquisition, e.g. workpiece identification · CPC title