Visual and Acoustic Analytics for Real-Time Industrial Event Detection

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Solution Overview

Problem

Traditional analytics for industrial processes rely on limited, expert-defined patterns and manual analysis, often failing to detect unknown abnormalities in real-time, and are costly to implement due to the need for intrusive sensor installations.

Innovation Solution

Implementing low-cost visual and acoustic analytics using commodity cameras and microphones to acquire data, which is analyzed by a machine learning engine to detect events and generate control signals, allowing for real-time monitoring and adaptation without requiring pre-defined patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional instrument-based data acquisition is used, then measurement reliability is improved, but device complexity and installation cost increase due to intrusive sensor installations and wiring

Engineering Contradiction:

Improvemeasurement reliabilityVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical/electrical sensors and wiring systems with visual (camera) and acoustic (microphone) sensing systems. This substitution eliminates the need for intrusive physical installations while maintaining measurement capabilities through non-contact data acquisition methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses visual and acoustic copies (images and sounds) of the industrial process environment to extract measurement information without physically interacting with the process. Cameras capture visual representations and microphones capture acoustic representations, which are then analyzed to detect events and abnormalities.

Inventive Principle:

Principle #26Copying

2Measurement precision

If expert-defined predetermined patterns are used for event detection, then detection accuracy for known events is improved, but adaptability to unknown abnormalities deteriorates

Engineering Contradiction:

Improveevent detection accuracyVSAvoiddetection adaptability

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent transitions from static, fixed patterns to dynamic, adaptive pattern recognition. The system continuously learns from new data and adapts its detection algorithms to identify both known and unknown abnormalities, making the detection capability evolve over time rather than remaining fixed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system performs self-learning and self-improvement by automatically analyzing visual and acoustic data to discover new patterns and abnormalities without requiring manual reprogramming. The algorithms adapt autonomously to detect both predetermined and previously unknown events.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If manual analysis of recorded data is performed, then analysis thoroughness is improved, but productivity and real-time detection capability deteriorate

Engineering Contradiction:

Improveanalysis thoroughnessVSAvoiddetection speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces manual human analysis with automated computer-based analysis of visual and acoustic data. This substitution enables real-time processing and detection while maintaining thorough analysis through sophisticated algorithms that can examine all data points without human limitations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system provides continuous automated analysis of incoming visual and acoustic data streams in real-time, eliminating the intermittent nature of manual analysis. The automated system continuously processes data without breaks, enabling both thorough and timely detection of events.

Inventive Principle:

Principle #20Continuity of useful action

4Quantity of substance

If comprehensive sensor installation is implemented, then coverage of monitored parameters is improved, but installation cost and intrusiveness increase

Engineering Contradiction:

Improvedata coverageVSAvoidinstallation ease

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent uses universal visual and acoustic sensing platforms that can monitor multiple process parameters simultaneously without requiring separate specialized sensors for each parameter. A single camera system can detect temperature changes, smoke, movement, and other visual indicators, while microphones can detect various acoustic signatures, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11188047B2Automatic visual and acoustic analytics for event detection

Publication Date: 2021.11.30 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

Systems and methods are provided for detecting events in industrial processes. An acquisition system may include one of a camera and an audio recorder to acquire monitoring data in the form of one of imaging data and acoustic data, respectively. A computer system, may include a machine learning engine and may be programmed to classify the monitoring data under a classifier, quantify, based on the classifier, the monitoring data with at least one quantifier, and detect an event when the at least one quantifier satisfies a predetermined rule corresponding to the at least one quantifier.