Facility Modeling System for Sensor Data Visualization
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Solution Overview
Problem
Current monitoring systems for machine parameters in industrial facilities require manual checks, leading to inefficiencies, increased costs, and safety concerns due to limited sensor data configuration and difficulty in identifying problematic parameters.
Innovation Solution
A facility modeling system that uses graphical representations and user interfaces to navigate and monitor machine parameters, allowing for customizable sensor data display and alert configurations, enabling efficient identification and addressing of issues through 3D and 2D models and sensor status visualization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If sensor data is collected and stored in a database for later access, then data availability is improved, but data accessibility and ease of identification deteriorate due to dense population making it difficult to identify problematic parameters
Solution Approach 1:
The patent transforms the dense two-dimensional chart data into a three-dimensional virtual model representation. This dimensional change allows users to navigate and identify problematic sensor parameters more easily by visually exploring the facility layout in 3D space, rather than searching through densely packed 2D charts. The 3D model provides spatial context that makes it intuitive to locate and assess machine parameters.
Solution Approach 2:
The patent creates a virtual copy or digital twin of the physical facility, including machines and sensor data. This virtual model serves as a simplified representation that maintains all sensor information while presenting it in an easily navigable format. Users can interact with the virtual copy to identify and analyze problematic parameters without dealing with the complexity of the original dense database charts.
2Measurement precision
If manual checks of sensors are performed regularly, then monitoring accuracy is improved, but time consumption and operational efficiency deteriorate
Solution Approach 1:
The system implements automated self-monitoring of sensor data through the virtual model. Sensors continuously transmit data to the system, which automatically updates the virtual facility model and highlights problematic parameters. This eliminates the need for manual sensor checks while maintaining continuous monitoring accuracy, as the system serves itself by automatically detecting and presenting issues that require attention.
Solution Approach 2:
The system establishes continuous feedback loops where sensor data is automatically collected, processed, and displayed in the virtual model. When parameters exceed thresholds or show anomalies, the system provides immediate feedback by highlighting the affected areas in the virtual facility representation. This automated feedback mechanism maintains monitoring precision without requiring manual intervention, significantly reducing time consumption.
3Reliability
If alarm systems are configured to sound alerts when parameters exceed thresholds, then safety monitoring is improved, but operational disruption and information completeness deteriorate due to limited configuration options
Solution Approach 1:
The alarm system transitions from static, pre-configured thresholds to dynamic, context-aware alerting. The virtual model provides visual context about the severity and location of parameter deviations, allowing operators to prioritize responses based on the actual situation rather than uniform alarm signals. The system can dynamically adjust alert presentation based on the specific parameter, machine, and facility context, reducing unnecessary disruptions while maintaining safety monitoring.
Solution Approach 2:
The alarm system is segmented into multiple visual indicators distributed throughout the virtual facility model, rather than a single centralized alarm. Each problematic parameter or machine can be highlighted independently with appropriate visual cues (colors, icons, animations). This segmentation allows operators to identify and address specific issues without being overwhelmed by unified alarm signals, providing more complete information about the nature and location of problems.
Data Source
AI summary
A facility modeling system renders graphical representations of machines and their environment in a facility model to facilitate monitoring of machine parameters and health. A sensor control module communicates with a plurality of sensors detecting machine parameter data for machines housed in a facility. The machine parameters may include any information that may directly or indirectly indicate the status of a machine or a part of a machine. The information collected from the sensors is incorporated into the facility model (a graphical rendering of the facility) which may provide any of a variety of multi-dimensional views of the facility. A GUI allows a user to navigate through the facility model to identify and monitor the status of the sensors. The sensor status may be indicated by an icon, callout, change in a display characteristic of a facility, machine, part, space, or item, a combination of these, and the like.