METHODS AND SYSTEMS FOR DATA COLLECTION, LEARNING, AND STREAMING OF MACHINE SIGNALS FOR ANALYTICS AND MAINTENANCE USING THE INDUSTRIAL INTERNET OF THINGS

Abstract

A system for predicting a service event from vibration data generally includes an industrial machine comprising at least one vibration sensor disposed to capture vibration of a portion of the industrial machine; a vibration analysis circuit in communication with the at least one vibration sensor; a multi-segment vibration frequency spectra structure that facilitates mapping the captured vibration to one vibration frequency segment of a multi-segment vibration frequency; a severity unit algorithm that receives the frequency of the captured vibration and the corresponding vibration frequency segment and produces a severity value which is then mapped to one of a plurality of severity units defined for the corresponding vibration frequency segment; and a signal generating circuit that receives the one of the plurality of severity units, and based thereon, signals a predictive maintenance server to execute a corresponding maintenance action on the portion of the industrial machine.

Claims

1. A system for predicting a service event from vibration data, comprising: an industrial machine comprising at least one vibration sensor disposed to capture vibration of a portion of the industrial machine; a vibration analysis circuit in communication with the at least one vibration sensor and that generates at least one of a frequency, peak amplitude, and gravitational force of the captured vibration; a multi-segment vibration frequency spectra structure that facilitates mapping the captured vibration to one vibration frequency segment of a multi-segment vibration frequency; a severity unit algorithm that receives the frequency of the captured vibration and the corresponding vibration frequency segment and produces a severity value which is then mapped to one of a plurality of severity units defined for the corresponding vibration frequency segment; and a signal generating circuit that receives the one of the plurality of severity units, and based thereon, signals a predictive maintenance server to execute a corresponding maintenance action on the portion of the industrial machine.

2. The system of claim 1, wherein the multi-segment vibration frequency spectra structure facilitates a mapping of the detected vibrations to a first severity unit when the frequency of the captured vibration corresponds to a below a low-end knee threshold-range of the multi-segment vibration frequency spectra.

3. The system of claim 1, wherein the multi-segment vibration frequency spectra structure facilitates a mapping of the detected vibrations to a second severity unit when the frequency of the captured vibration corresponds to a mid-range of the multi-segment vibration frequency spectra.

4. The system of claim 1, wherein the multi-segment vibration frequency spectra structure facilitates a mapping of the detected vibrations to a third severity unit when the frequency of the captured vibration corresponds to an above a high-end knee threshold-range of the multi-segment vibration frequency spectra.

5. The system of claim 1, wherein the severity units indicate that the detected vibrations may lead to a failure of at least the portion of the industrial machine.

6. The system of claim 1, wherein a first segment of the multi-segment vibration frequency spectra is divided into a plurality of severity units based on the amplitude of the captured vibration.

7. The system of claim 1, wherein a second segment of the multi-segment vibration frequency spectra is divided into a plurality of severity units based on the gravitational force of the captured vibration.

8. The system of claim 1, wherein the severity unit is determined based on a peak displacement of the amplitude of the captured vibration for determined vibration frequencies within a first segment of the multi-segment vibration frequency spectra.

9. The system of claim 1, wherein the severity unit is determined based on gravitational force of the captured vibration for determined vibration frequencies within a second segment of the multi-segment vibration frequency spectra.

10. The system of claim 1, wherein the portion of the industrial machine is a moving part.

11. The system of claim 1, wherein the portion of the industrial machine is a structural member supporting a moving part.

12. The system of claim 1, wherein the portion of the industrial machine is a motor.

13. The system of claim 1, wherein the portion of the industrial machine is a drive shaft.

14. A method comprising: sampling a signal at a streaming sample rate, thereby producing a plurality of samples of the signal; allocating, with a signal routing circuit, a first portion of the plurality of samples of the signal to a first signal analysis circuit, the portion selected based on a first signal analysis sampling rate that is less than the streaming sample rate; allocating, with a signal routing circuit, a second portion of the plurality of samples of the signal to a second signal analysis circuit, the portion selected based on a second signal analysis sampling rate that is less than the streaming sample rate; and storing the plurality of samples of the signal, an output of the first signal analysis circuit, and an output of the second signal analysis circuit, wherein the allocated first portion in the stored plurality of samples and the allocated second portion in the stored plurality of samples are tagged with indicia that references the corresponding stored signal analysis output.

15. The method of claim 14, wherein allocating with the signal routing circuit comprises integrating a plurality of samples based on a ratio of the signal analysis sampling rate and the streaming sample rate.

16. The method of claim 14 wherein allocating with the signal routing circuit comprises selecting samples of the signal based on a ratio of the signal analysis sampling rate and the streaming sample rate.

17. The method of claim 14, wherein the streaming sample rate is at least twice as fast as a dominant frequency of the signal.

18. The method of claim 14, wherein a ratio of the signal analysis sampling rate to the streaming sample rate determines a number of supplemental binary bits of data of the output of the first and second signal analysis circuits.

19. The method of claim 18, wherein the number of supplemental binary bits comprises one when the streaming sample rate is at least twice and less than four times the signal analysis sampling rate.

20. The method of claim 18, wherein the number of supplemental binary bits comprise two when the streaming sample rate is at least four times and less than eight times the signal analysis sampling rate.