Component Digital Twins for Visual Industrial Fault Prediction
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Solution Overview
Problem
Industrial environments face challenges in efficiently processing vast amounts of data from multiple sensors to diagnose faults and optimize operations, due to the complexity and sheer size of the data, leading to difficulties in predicting maintenance needs and improving uptime.
Innovation Solution
A computer-implemented method using a plurality of sensors to generate sensor data values, which are processed to determine recognized patterns, and used to update digital twins of industrial components, allowing for visual rendering and simulation of operational conditions, enabling fault diagnosis and maintenance optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vast amounts of sensor data are collected from multiple sensors in industrial environments, then the ability to predict maintenance needs and diagnose faults is improved, but the complexity and difficulty of processing the data increases significantly
Solution Approach 1:
The patent segments the complex data processing task by creating separate digital twins for different industrial components (motors, pumps, compressors, etc.). Each digital twin independently processes sensor data specific to its component type, breaking down the overwhelming bulk data processing into manageable, component-specific analysis units that can be handled separately.
Solution Approach 2:
The patent introduces digital twins as intermediary entities between the raw sensor data and the fault diagnosis system. These digital twins act as mediators that receive, process, and interpret sensor data from physical components, transforming raw data into meaningful diagnostic information without requiring direct complex processing of all raw data streams.
2Measurement precision
If digital twins are updated in real-time based on sensor data values, then the accuracy of operational condition visualization is improved, but the computational resources and processing time required increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring digital twins with component-specific parameters, characteristics, and expected operational ranges before deployment. This pre-preparation allows the digital twins to quickly process and compare incoming sensor data against predetermined criteria, reducing the time needed for real-time analysis while maintaining high accuracy.
Solution Approach 2:
The patent utilizes parameter changes by dynamically updating specific operational parameters of digital twins based on incoming sensor data. Rather than reprocessing entire data sets, the system selectively updates relevant parameters (temperature, vibration, pressure, etc.) in the digital twins, enabling efficient real-time tracking of component conditions with minimal computational overhead.
3Ease of operation
If visual rendering of digital twins is provided to show operational conditions, then the ease of operation and user understanding is improved, but the computational load and energy consumption increase
Solution Approach 1:
The patent creates visual copies (digital twins) of physical industrial components that replicate their operational characteristics in a simplified digital form. These visual representations provide users with intuitive understanding of component conditions without requiring direct interaction with complex sensor data or diagnostic algorithms, reducing the cognitive energy users would otherwise expend on interpreting raw data.
Data Source
AI summary
Computer-implemented methods for fault diagnosis in an industrial environment generally includes processing the plurality of sensor data values to determine a recognized pattern therefrom; retrieving at least one industrial-environment digital twin corresponding to the industrial environment, the at least one industrial-environment digital twin comprising a plurality of component digital twins, with each of the plurality of component digital twins corresponding to one of the plurality of components in the industrial environment, and wherein the at least one industrial-environment digital twin and the plurality of component digital twins are visual digital twins that are configured to be rendered in a visual manner; and rendering the at least one industrial-environment digital twin and the at least one respective component digital twin corresponding to the particular component in the client application in response to the received request and based on the operational condition of the particular component.