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

Patent metadata

Field	Value
Publication number	US-2022011739-A1
Application number	US-202117449176-A
Country	US
Kind code	A1
Filing date	Sep 28, 2021
Priority date	Nov 13, 2018
Publication date	Jan 13, 2022
Grant date	—

Abstract

A system includes a first asset and a second asset disposed at an industrial system, and a server 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 and generate a model for the second asset based on the first set of stream-based data, wherein the model is configured to output an expected set of stream-based data associated with the second asset; receive a second set of stream-based data from the second asset; and send a command to the first asset or the second asset in response to the second set of stream-based data being outside of a threshold from the expected set of stream-based data.

First claim

1 . A system, comprising:
a server communicatively coupled to a first asset disposed at an industrial automation system and a second asset disposed at the industrial automation system, wherein the server is configured to:
receive a first set of stream-based data from the first asset;
generate a modeled condition for the second asset based on the first set of stream-based data;
generate an expected set of stream-based data associated with the second asset using the modeled condition for the second asset;
receive a second set of stream-based data from the second asset; and
send a command to the first asset or the second asset in response to the second set of stream-based data being outside of a threshold from the expected set of stream-based data.

2 . The system of claim 1 , wherein the first asset is disposed at a first node in the industrial automation system.

3 . The system of claim 2 , wherein the second asset is disposed at a second node that is downstream of the first node.

4 . The system of claim 3 , wherein the modeled condition is generated using a model based on one or more raw measurements taken at the first node, wherein the one or more raw measurements comprise temperature, pressure, and flow rate.

5 . The system of claim 3 , wherein the modeled condition is generated using a model based on based on an underlying condition at the first node.

6 . The system of claim 3 , wherein the modeled condition is generated using a model based on a state of the first asset at the first node.

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

8 . The system if 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.

9 . A method, comprising:
receiving a first set of stream-based data from a first asset disposed at an industrial automation system; generating a modeled condition for a second asset disposed at the industrial automation system based on the first set of stream-based data; generating an expected set of stream-based data associated with the second asset using the modeled condition for the second asset; receiving a second set of stream-based data from the second asset; and sending a command to the first asset or the second asset in response to the second set of stream-based data being outside of a threshold from the expected set of stream-based data.

10 . The method of claim 9 , wherein the first asset is disposed at a first node in the industrial automation system.

11 . The method of claim 10 , wherein the second asset is disposed at a second node that is downstream of the first node.

12 . The method of claim 11 , wherein the modeled condition is generated using a model based on one or more raw measurements taken at the first node, wherein the one or more raw measurements comprise temperature, pressure, and flow rate.

13 . The method of claim 11 , wherein the modeled condition is generated using a model based on based on an underlying condition at the first node.

14 . The method of claim 11 , wherein the modeled condition is generated using a model based on a state of the first asset at the first node.

15 . The method of claim 9 , further comprising:
monitoring a first alarm limit drift with respect to a first portion of the first set of stream-based data; and adjusting a second alarm limit for a second portion of the second set of data based on the first alarm drift.

16 . The method if claim 9 , wherein the industrial system comprises a chemical processing system, a food and beverage processing system, a hydrocarbon extraction system, or a mining system.

17 . A non-transitory computer-readable medium having stored thereon instructions that, in response to execution, cause a system comprising a processor to perform operations, the operations comprising:
receiving a first set of stream-based data from a first asset disposed at an industrial automation system; generating a modeled condition for a second asset disposed at the industrial automation system based on the first set of stream-based data; generating an expected set of stream-based data associated with the second asset using the modeled condition for the second asset; receiving a second set of stream-based data from the second asset; and sending a command to the first asset or the second asset in response to the second set of stream-based data being outside of a threshold from the expected set of stream-based data.

18 . The non-transitory computer-readable medium of claim 17 , wherein the first asset is disposed at a first node in the industrial automation system.

19 . The non-transitory computer-readable medium of claim 18 , wherein the second asset is disposed at a second node that is downstream of the first node.

20 . The non-transitory computer-readable medium of claim 19 , wherein the modeled condition is generated using a model based on one or more raw measurements taken at the first node, wherein the one or more raw measurements comprise temperature, pressure, and flow rate.

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

• 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

• G05B19/406 Primary

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

• G05B2219/31282

  Data acquisition, BDE MDE · CPC title