PLC Acoustic Anomaly Detection for Real-Time Quality Inspection

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Solution Overview

Problem

Current acoustic anomaly detection in industrial settings relies on dedicated systems without direct integration with factory automation systems, requiring human intervention and leading to inefficiencies and subjectivity in quality checks.

Innovation Solution

An automated acoustic anomaly detection system integrated with programmable logic controllers (PLCs) using machine learning algorithms and AI accelerators, enabling real-time classification of acoustic emissions as normal or anomalous, and directly interfacing with industrial automation systems for seamless integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If dedicated acoustic DAQ systems are used for anomaly detection, then measurement precision is improved, but device complexity increases and integration with factory automation systems is lost

Engineering Contradiction:

Improveacoustic anomaly detection precisionVSAvoidsystem integration complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the acoustic anomaly detection functionality with the existing PLC system by integrating a microphone sensor and acoustic analysis algorithm directly into the controller. This consolidation eliminates the need for separate dedicated DAQ systems while maintaining detection capabilities and restoring direct integration with the factory automation system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PLC system is enhanced to perform multiple functions: its existing control capabilities plus new acoustic anomaly detection capabilities. By making the PLC multi-functional, the system eliminates the need for separate dedicated acoustic systems while maintaining both control and detection functions within a single integrated platform.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If human inspectors are used for acoustic quality checks, then adaptability to complex anomalies is improved, but productivity decreases and human error is introduced

Engineering Contradiction:

Improveanomaly detection adaptabilityVSAvoidproduction line speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces the mechanical human inspection process with an automated electronic system consisting of a microphone sensor and signal processing algorithm running on the PLC. This substitution eliminates human limitations while maintaining the ability to detect various acoustic anomalies, thereby increasing productivity without sacrificing detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the production line to perform its own quality inspection automatically. The PLC continuously monitors acoustic emissions and autonomously identifies anomalies without requiring external human intervention, allowing the process to serve itself and maintain high productivity.

Inventive Principle:

Principle #25Self-service

3Reliability

If human intervention is required for acoustic inspection, then detection of complex anomalies is improved, but loss of time increases due to manual processing

Engineering Contradiction:

Improveanomaly detection reliabilityVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The automated acoustic monitoring system operates continuously without interruption, constantly analyzing acoustic emissions from products on the production line. This continuous operation eliminates the time losses associated with manual inspection cycles while maintaining reliable detection through uninterrupted monitoring and immediate anomaly identification.

Inventive Principle:

Principle #20Continuity of useful action

4Measurement precision

If dedicated acoustic systems are used, then measurement precision is improved, but extent of automation decreases due to lack of integration

Engineering Contradiction:

Improveacoustic detection precisionVSAvoidautomation system integration

Core Design Contradiction:

Measurement precisionVSExtent of automation

Solution Approach 1:

The patent merges acoustic detection functionality with the automated PLC system, creating a unified automated solution. The microphone sensor and analysis algorithm are integrated directly into the controller that already automates production processes, thereby maximizing the extent of automation while maintaining precise acoustic detection capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240328903A1Automated acoustic anomaly detection feature deployed on a programmable logic controller

Publication Date: 2024.10.03 SIEMENS AG

AI summary

A real-time computer system for automated acoustic anomaly detection in a programmable logic controller (PLC) is disclosed, the computer system being deployed onto a backplane of the PLC. The computer system includes at least one processor with a real-time operating system and a memory having algorithmic modules stored thereon executable by the processor. The modules include a digital signal processing module configured to apply a windowing function to the sound signal data captured by a sensor, the sound signal data representative of sound emitted by an energized work product under quality inspection. The modules further include a feature extraction component configured to extract acoustic features from each sound window, and an anomaly detector module configured to operate a machine learning-based model to execute acoustic anomaly detection according to results of a classification operation on the acoustic features.