Systems and methods for assessing a facility based on audio/visual delta analysis

Patent metadata

Field	Value
Publication number	US-9805460-B2
Application number	US-201514870937-A
Country	US
Kind code	B2
Filing date	Sep 30, 2015
Priority date	Mar 27, 2015
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

In one embodiment, a system may include a multi-purpose sensor coupled to a machine operating in an industrial environment. The multi-purpose sensor may include a camera that obtains a first and second set of image data including images of the machine and an environment surrounding the machine. The first set of image data is associated with a baseline of the machine and the environment, and the second set of image data is acquired subsequent to when the first set is acquired. The system may include a computing device that may include a processor to receive the first and second set of image data, determine baseline positions of objects in the first set, determine subsequent positions of the objects in the second set, determine whether the subsequent positions vary from the baseline positions, and perform an action when the subsequent positions vary from the baseline positions.

First claim

The invention claimed is:

1. A system comprising:
a multi-purpose sensor configured to couple to a machine operating in an industrial environment, comprising:
a camera configured to obtain a first set of image data and a second set of image data comprising images of the machine and an environment surrounding the machine, wherein the first set of image data is associated with a baseline of the machine and the environment, and wherein the second set of image data is acquired subsequent to when the first set of image data is acquired;
a plurality of sensors configured to acquire a plurality of different types of sets of data associated with the machine or the environment, wherein the plurality of different types of sets of data comprises historical sensor measurements for each of the plurality of sensors over time when the machine is operating efficiently; and
a first processor configured to:
determine a baseline individual measurement signature for each of the plurality of sensors based on the plurality of different types of sets of data, a collective measurement signature for the plurality of sensors based on the plurality of different types of sets of data, or both, wherein the baseline individual measurement signature and the collective measurement signature are associated with when the machine is operating efficiently;
determine one or more baseline machine settings, one or more baseline machine operational parameters, or both associated with the baseline individual measurement signature, the collective measurement signature, or both; and
monitoring and modifying one or more current machine settings, one or more current machine operational parameters, or both to match the baseline machine settings, the baseline machine operational parameters, or both; and

a computing device configured to communicatively couple to the multi-purpose sensor, wherein the computing device comprises:
a second processor configured to:
receive the first set of image data and the second set of image data from the multi-purpose sensor;
determine one or more baseline positions of one or more objects in the first set of image data;
determine one or more subsequent positions of the one or more objects in the second set of image data;
determine whether the subsequent positions vary from the baseline positions; and
perform an action when the subsequent positions vary from the baseline positions.

2. The system of claim 1 , wherein the first set of image data is acquired by the camera when the machine is operating normally.

3. The system of claim 1 , wherein:
the first processor is configured to determine whether a hazard is present within a proximity of the machine based on the first set of image data and the second set of image data; and
perform a second action when the hazard is present.

4. The system of claim 1 , wherein:
a first portion of the plurality of different types of sets of data comprises historical sensor measurements over time when the machine is operating normally for each of the plurality of sensors; and
a second portion of the plurality of different types of sets of data comprises sensor measurements subsequent to when the first portion is acquired for each of the plurality of sensors.

5. The system of claim 4 , wherein the first processor configured to:
determine a baseline individual measurement signature for each of the plurality of sensors based on the first portion of the plurality of different types of sets of data;
determine a subsequent individual measurement signature based on the second portion of the plurality of different types of sets of data;
determine whether the subsequent individual measurement signature varies from the respective baseline individual measurement signature;
generate one or more signals when the subsequent individual measurement signature varies from the respective baseline individual measurement signature, wherein the one or more signals are configured to cause the computing device, a cloud-based computing system, a control/monitoring device, or some combination thereof to perform a preventative action, diagnostic, predictive operation, or some combination thereof; and
transmit the one or more signals to the computing device, the cloud-based computing system, the control/monitoring device, or some combination thereof.

6. The system of claim 1 , wherein the first set of image data and the second set of image data are taken within a visible light range or outside the visible light range.

7. The system of claim 6 , wherein the first set of image data and the second set of image data are taken within an infrared light range.

8. The system of claim 1 , wherein the first set of image data and the second set of image data are taken within an ultraviolet light range.

9. The system of claim 1 , wherein the first processor is configured to:
determine one or more subsequent individual measurement signatures for each of the plurality of sensors, a subsequent collective measurement signature, or both;
determine when any of the subsequent individual measurement signatures, the subsequent collective measurement signature, or both deviate from the baseline individual measurement signature, the collective measurement signature, or both; and
modify one or more current machine settings, one or more current machine operational parameters, or both to cause the subsequent individual measurement signatures, the subsequent collective measurement signature, or both to converge toward the respective baseline individual measurement signatures, the collective measurement signature, or both.

10. The system of claim 1 , wherein the first processor configured to determine one or more baseline machine settings, one or more baseline machine operational parameters, or both when the machine is producing a desired quantity of products with a certain level of quality based on a first set of data acquired by a plurality of sensors disposed within the multi-purpose sensing device.

11. The system of claim 10 , wherein the first processor is configured to modify one or more current machine settings, one or more current machine operational parameters, or both when a second set of data acquired after the first set of data deviates from the first set of data.

12. A tangible, non-transitory computer readable medium storing instructions that, when executed by a processor, are configured to cause the processor to:
transmit a first set of image data and a second set of image data acquired by a camera of a multi-purpose sensor to a cloud-based computing system, wherein the first and second sets of image data comprise an image of a machine in an industrial automation application, an image of an environment surrounding the machine, or both, and wherein the second set of image data is acquired subsequent to when the first set of image data is acquired;
receive a plurality of different types of sets of data associated with the machine or the environment from a plurality of sensors disposed within the multi-purpose sensor, wherein the plurality of different types of data comprises historical sensor measurements for each of the plurality of sensors over time when the machine is operating efficiently;
determine a baseline individual measurement signature for each of the plurality of sensors based on the plurality of different types of sets of data, a collective measurement signature for the plurality of sensors based on the plurality of different types of sets of data, or both, wherein the baseline individual measurement signature and the collective measurement signature are associated with when the machine is operating efficiently;
determine one or more baseline machine settin

Assignees

• Rockwell Automation Tech Inc

Inventors

• Michalscheck Jimi R
• Michalscheck Kelly A
• Korpela Jessica L
• Reissner Kyle K
• Vasko David A
• Fordenwalt Matthew W
• Jauquet John J
• Ericsson Matthew R
• Wilber Andrew

Classifications

• G05B2219/31483

  Verify monitored data if valid or not by comparing with reference value · CPC title

• G05B23/0283

  Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] (preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06) · CPC title

• G05B2219/37325

  Multisensor integration, fusion, redundant · CPC title

• G05B23/0224

  Process history based detection method, e.g. whereby history implies the availability of large amounts of data · CPC title

• G05B2219/33286

  Test, simulation analysator · CPC title