METHODS AND SYSTEMS FOR INDUSTRIAL INTERNET OF THINGS DATA COLLECTION FOR A CHEMICAL PRODUCTION PROCESS

Abstract

A system, method and apparatus for data collection in an industrial production environment are described. The system may include, a data acquisition circuit structured to interpret a plurality of detection values, each of the plurality of detection values corresponding to input received from at least one of a plurality of input sensors which includes a detection package, each of the plurality of input sensors operatively coupled to at least one of a plurality of components of an industrial production process, a data analysis circuit structured to analyze a subset of the plurality of detection values to determine a sensor performance value of at least one of the plurality of input sensors, and an analysis response circuit structured to adjust at least one of a sensor scaling value or a sensor sampling frequency value, in response to the sensor performance value.

Claims

1. A system for data collection in an industrial production environment, the system comprising: a data acquisition circuit structured to interpret a plurality of detection values, each of the plurality of detection values corresponding to input received from at least one of a plurality of input sensors which comprise a detection package, each of the plurality of input sensors operatively coupled to at least one of a plurality of components of an industrial production process; a data analysis circuit structured to analyze a subset of the plurality of detection values to determine a sensor performance value of at least one of the plurality of input sensors; and an analysis response circuit structured to adjust at least one of: a sensor scaling value or a sensor sampling frequency value, in response to the sensor performance value.

2. The system for data collection of claim 1, wherein the industrial production environment comprises at least one of a chemical production process or a pharmaceutical production process.

3. The system for data collection of claim 1, wherein the analysis response circuit is further structured to perform, in response to the sensor performance value, at least one operation selected from the operations consisting of: enabling or disabling at least one of the plurality of sensors; modifying a sensor parameter of at least one of the plurality of input sensors; switching between two or more of the plurality of input sensors having distinct performance parameters; and switching between two or more of the plurality of input sensors having distinct locations.

4. The system for data collection of claim 1, further comprising data storage having at least one of calibration data or maintenance history data for at least one of the plurality of input sensors stored thereupon, and wherein the data acquisition circuit is further structured to calibrate the at least one of the plurality of input sensors in response to the sensor performance value.

5. The system for data collection of claim 1, wherein the data analysis circuit is further structured to: determine a current status of at least one of: at least one of the plurality of components or a production process; and wherein the current status of the at least one of the plurality of components or the production process comprises at least one of: a current state of the one of the plurality of components, a current condition of the one of the plurality of components, a current stage of the production process, and a confirmation of the current stage of the production process.

6. The system for data collection of claim 1, wherein the data analysis circuit is further structured to: determine a future status of at least one of: at least one of the plurality of components or a production process; and wherein the future status of the at least one of the plurality of components or the production process comprises at least one of: a future state of the at least one of the plurality of components, a future condition of the at least one of the plurality of components, a future stage of the production process, and a confirmation of the future stage of the production process.

7. The system for data collection of claim 5, wherein the analysis response circuit is further structured to adjust the detection package in response to the current status of the at least one of the plurality of components or the production process.

8. The system for data collection of claim 5, wherein: the current status of the at least one of the plurality of components or the production process comprises at least one value selected from the values consisting of: a process failure value, an off-nominal process value, a sensor failure value, and a maintenance requirement value; and wherein the analysis response circuit is further structured, in response to the current status of the at least one of the plurality of components or the production process, to perform at least one operation selected from the operations consisting of: recommending an action; initiating a maintenance call; recommending a maintenance operation at an upcoming process stop, recommending changes in at least one of process parameters or operating parameters, changing an operating speed of the at least one of the plurality of components, initiating amelioration of an issue, and signaling for an alignment process.

9. A computer-implemented method for monitoring data collection for an industrial production process, the method comprising: interpreting a plurality of detection values, each of the plurality of detection values corresponding to input received from at least one of a plurality of input sensors which comprise a detection package, each of the plurality of input sensors operatively coupled to at least one of a plurality of components of the industrial production process; analyzing a subset of the plurality of detection values to determine a sensor performance value of at least one of the plurality of input sensors; and adjusting at least one of: a sensor scaling value or a sensor sampling frequency value, in response to the sensor performance value.

10. The method of claim 9, further comprising, in response to the sensor performance value, performing at least one of: enabling or disabling at least one of the plurality of sensors; modifying a sensor parameter of at least one of the plurality of input sensors; switching between two or more of the plurality of input sensors having distinct performance parameters; and switching between two or more of the plurality of input sensors having distinct locations.

11. The method of claim 9, wherein the industrial production process comprises at least one of a chemical production process or a pharmaceutical production process.

12. The method of claim 9, further comprising: determining a current status of at least one of: at least one of the plurality of components or a production process; and wherein the current status of the at least one of the plurality of components or the production process comprises at least one of: a current state of the at least one of the plurality of components, a current condition of the at least one of the plurality of components, a current stage of the production process, and a confirmation of the current stage production process.

13. The method of claim 9, further comprising: determining a future status of at least one of: at least one of the plurality of components or a production process; and wherein the future status of the at least one of the plurality of components or the production process comprises at least one of: a future state of the at least one of the plurality of components, a future condition of the at least one of the plurality of components, a future stage of the production process, and a confirmation of the future stage production process.

14. The method of claim 12, wherein: the current status of the at least one of the plurality of components or the production process comprises at least one value selected from the values consisting of: a component failure value, a process failure value, an off-nominal process value, a sensor failure value, and a maintenance required value; and in response to the current status of the at least one of the plurality of components or the production process, performing at least one operation selected from the operations consisting of: recommending an action; initiating a maintenance call; recommending a maintenance operation at an upcoming process stop, recommending changes in at least one of a process parameter or an operating parameter, changing an operating speed of the at least one of the plurality of components, initiating amelioration of an issue, and signaling for an alignment process.

15. A monitoring apparatus for data collection in an industrial production environment, the apparatus comprising: a data acquisition component configured to interpret a plurality of detection values, each of the plurality of detection values corresponding to input received from at least one of a plurality of input sensors which comprise a detection package, each of the plurality of input sensors operatively coupled to at least one of a plurality of components of an industrial production process; a data analysis component configured to analyze a subset of the plurality of detection values, and to determine a sensor performance value of at least one of the plurality of input sensors; and an analysis response component configured to adjust at least one of: a sensor scaling value and a sensor sampling frequency value, in response to the sensor performance value.

16. The apparatus of claim 15, wherein the industrial production process comprises at least one of a chemical production process or a pharmaceutical production process.

17. The apparatus of claim 15, wherein the analysis response component is further configured to perform, in response to the sensor performance value, at least one operation selected from the operations consisting of: enabling or disabling at least one of the plurality of sensors; modifying a sensor parameter of at least one of the plurality of input sensors; switch between two or more of the plurality of input sensors having distinct performance parameters; and switch between two or more of the plurality of input sensors positioned at distinct locations.

18. The apparatus of claim 15, wherein the data analysis component is further configured to: determine a current status of at least one of: at least one of the plurality of components or a production process; and wherein the current status of the at least one of the plurality of components or the production process comprises at least one of: a current state of one of the at least one of the plurality of components, a current condition of the at least one of the plurality of components, a current stage of the production process, and a confirmation of the current stage of the production process.

19. The apparatus of claim 15, wherein the data analysis component is further configured to: determine a future status of at least one of: at least one of the plurality of components or a production process; and wherein the future status of the at least one of the plurality of components or the production process comprises at least one of: a future state of the at least one of the plurality of components, a future condition of the at least one of the plurality of components, a future stage of the production process, and a confirmation of the future stage production process.

20. The apparatus of claim 19, wherein: the current status of the at least one of the plurality of components or the production process comprises at least one value selected from the values consisting of: a component failure value, a process failure value, an off-nominal process value, a sensor failure value, and maintenance required value; and the analysis response circuit is further structured, in response to the current status of the at least one of the plurality of components or the production process, to perform at least one operation selected from the operations consisting of: recommending an action; initiating a maintenance call; recommending maintenance at an upcoming process stop, recommending changes in at least one of process parameters or operating parameters, changing an operating speed of the at least one of the plurality of components, initiating amelioration of an issue, and signaling for an alignment process.