Methods and systems for data acquisition, learning, and streaming of machine signals for analysis and maintenance using the Internet of Things in industrial applications.

Abstract

To collect, discover, capture, disseminate, manage, and process information related to industrial machinery. [Solution] The industrial machine predictive maintenance system includes: an industrial machine data analysis facility that applies machine learning to data representing a portion of the state of industrial machines received via a data collection network to generate a stream of industrial machine health monitoring data; an industrial machine predictive maintenance facility that applies machine failure detection and classification algorithms to generate industrial machine service recommendations in response to health monitoring data; a computerized maintenance management system that generates service and parts orders and / or requests in response to industrial machine service recommendations; and a service and delivery coordination facility that processes information on services performed on industrial machines in response to orders and / or service and parts requests, and verifies the services performed while generating a ledger of service activities and results for individual industrial machines.

Claims

1. Using one or more vibration sensors in a portable device, generate vibration data representing the measured vibrations of at least a portion of an industrial machine. Mapping the aforementioned vibration data to one or more severity units, and A method for using severity units for predictive maintenance of industrial machinery, by determining maintenance operations to be performed on at least a portion of the industrial machinery based on the severity units.

2. Mapping the aforementioned vibration data to one or more severity units is, Mapping a portion of the vibration data having frequencies below the low-end knee threshold range of the vibration frequency spectrum to a first severity unit, The portion of the vibration data having frequencies corresponding to the intermediate region of the vibration frequency spectrum is mapped to the second severity unit, and The method according to claim 1, comprising mapping the portion of the vibration data having frequencies corresponding to or exceeding the high-end knee threshold range of the vibration frequency spectrum to the third severity unit.

3. The method according to claim 1, wherein the mapping of the vibration data to one or more severity units is performed by the portable device.

4. The method according to claim 1, wherein the mapping of the vibration data to one or more severity units is performed on a server, and the method further includes transmitting the vibration data from the portable device to the server.

5. Using the collective processing mind associated with the portable device, detect that the portable device is in close proximity to the industrial machine. A first command to cause the portable device to generate vibration data is transmitted from the collective processing mind to the portable device, and The method according to claim 1, further comprising, after generating the vibration data, sending a second command from the collective processing mind to the portable device to cause the collective processing mind to transmit the vibration data.

6. The method according to claim 1, wherein the portable device is a mobile phone.

7. The method according to claim 1, wherein the portable device is a laptop computer.

8. The method according to claim 1, wherein the portable device is a tablet computer.

9. The method according to claim 1, wherein the portable device is a personal digital assistant.

10. The method according to claim 1, wherein the portable device is a transceiver.

11. The method according to claim 1, wherein the portable device is a wireless device.

12. The method according to claim 1, wherein the portable device is a long-range communication device.

13. The method according to claim 1, wherein the portable device is a short-range communication device.

14. The method according to claim 1, wherein the portable device is a flashlight.

15. An industrial machine including at least one vibration sensor positioned to capture vibrations of a part of the industrial machine, A motion data collector that collects vibrations captured from at least one of the vibration sensors and generates vibration data, A multi-segment vibration frequency spectral structure that facilitates mapping captured vibrations to one vibration frequency segment of a multi-segment vibration frequency, A severity unit algorithm that takes the frequency of vibration and the corresponding vibration frequency segment and generates a severity value mapped to one of several severity units defined for the corresponding vibration frequency segment, A system including a signal generating circuit that receives one of the plurality of severity units and signals the predictive maintenance server to perform a maintenance operation corresponding to the part of the industrial machine based on it.

16. The system according to claim 15, wherein the mobile data collector is a mobile robot.

17. The system according to claim 15, wherein the mobile data collector is a mobile vehicle.

18. The system according to claim 15, wherein the mobile data collector is a portable device.

19. The system according to claim 15, wherein the mobile data collector is a wearable device.

20. The system according to claim 15, wherein the segments of the multisegment vibration frequency spectrum that constrain the vibration are determined by mapping the vibration to one of several severity units based on the determined segments, each of which severity units corresponds to a different range of the multisegment vibration frequency spectrum.

21. The severity unit algorithm maps the captured vibrations to one vibration frequency segment of a multi-segment vibration frequency, When the frequency of the vibration corresponds to a range less than the low-end knee threshold of the multi-segment vibration frequency spectrum, the vibration is mapped to the first severity unit. When the frequency of the vibration corresponds to the intermediate region of the multi-segment vibration frequency spectrum, the vibration is mapped to the second severity unit, and The system according to claim 20, comprising mapping the vibration to the third severity unit when the frequency of the vibration corresponds to or exceeds the high-end knee threshold range of the multi-segment vibration frequency spectrum.

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