3D Model Overlay for Anomaly Detection in Equipment Maintenance
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Solution Overview
Problem
Existing systems for identifying and replacing failing equipment parts are inefficient, as they often require physical examination and lack accurate methods to match 3D models with actual equipment anomalies, leading to incorrect part ordering.
Innovation Solution
A system combining hardware and software that uses drones, robots, or electronic devices to inspect equipment, overlay 3D models, and employ anomaly detection units like thermal cameras and echolocation sensors to accurately identify failing parts and their associated kits, allowing for precise online ordering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical examination and manual identification methods are used to identify failing parts, then operators can detect part anomalies, but the process requires significant time, effort, and expertise while risking incorrect part identification
Solution Approach 1:
The patent replaces manual physical examination with automated sensing systems including thermal cameras, ultrasonic sensors, and vibration sensors that detect part anomalies without human intervention. These sensors substitute the mechanical inspection process, providing accurate identification while eliminating the time and expertise requirements of manual examination.
Solution Approach 2:
The patent creates a digital twin or virtual model of the equipment that mirrors the physical system. This digital copy allows operators to identify failing parts by comparing sensor data against the virtual model, enabling accurate part identification without physically examining each component, thus reducing both time and expertise requirements.
2Reliability
If operators follow maintenance schedules to replace parts, then preventive maintenance can be performed, but operators often fail to adhere to schedules and struggle to identify which specific parts need replacement
Solution Approach 1:
The patent implements continuous monitoring systems that provide real-time feedback on part conditions through sensor arrays. These sensors detect thermal changes, vibrations, and other anomalies, automatically identifying which specific parts are failing. This feedback mechanism eliminates the need for operators to manually track maintenance schedules or identify problematic parts, improving both adherence and ease of operation.
3Measurement precision
If equipment is uninstalled to identify broken parts, then complete inspection is possible, but the process takes excessive time and disrupts operations
Solution Approach 1:
The patent replaces physical disassembly with non-contact sensing technologies including thermal imaging, ultrasonic detection, and vibration analysis. These systems can penetrate or detect around equipment components without requiring uninstallation, providing complete inspection capability while maintaining equipment operational status and maximizing productivity.
4Ease of operation
If interactive exploded views are used to help users identify replacement parts, then users can visualize part locations, but the system still requires user interpretation and manual part selection
Solution Approach 1:
The patent integrates sensor data feedback directly with the visual interface, automatically highlighting the specific failing part on the exploded view diagram. The system correlates thermal, vibrational, and ultrasonic anomaly data with the corresponding physical component locations, eliminating the need for users to manually search or interpret symptoms. This automated feedback loop preserves complete anomaly location information while maximizing ease of operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate identification and replacement of failing parts without physical examination, ensuring correct part selection and reducing the time and effort required for maintenance, by using 3D models and anomaly detection technologies to confirm part locations with confidence factors.
Implementation Method 1
anomaly detection units like thermal cameras
Implementation Method 2
echolocation sensors
Data Source
AI summary
A system and method for determining a part having an anomaly in equipment and initiating electronic transaction for placing order to replace the part using three-dimensional (3D) model of equipment. The system inspects equipment to identify type of equipment and requests a data storage device storing 3D models of equipment to provide matching 3D models corresponding to equipment identified. The system utilizes various technologies to determine relative location of anomaly indicative of failing/failed part in equipment. The system overlays 3D image map from the 3D model to identify specific part/assembly/subassembly within the 3D model corresponding to the relative location of the anomaly. The system identifies additional parts associated with the failing/failed part as a kit in the 3D image map, and adds the kit to virtual shopping cart for initiating electronic transaction in reference to the kit depicted in the 3D model of equipment for replacement of the failing/failed part.