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

Abstract

An industrial machine predictive maintenance system generally includes a mobile data collector swarm comprising one or more mobile data collectors configured to collect health monitoring data representative of conditions of one or more industrial machines located in an industrial environment; an industrial machine predictive maintenance facility that produces industrial machine service recommendations responsive to the health monitoring data by applying machine fault detection and classification algorithms thereto; and a computerized maintenance management system (CMMS) that produces at least one of orders and requests for service and parts responsive to receiving the industrial machine service recommendations.

Claims

1. An industrial machine predictive maintenance system comprising: a mobile data collector swarm comprising one or more mobile data collectors configured to collect health monitoring data representative of conditions of one or more industrial machines located in an industrial environment; an industrial machine predictive maintenance facility that produces industrial machine service recommendations responsive to the health monitoring data by applying machine fault detection and classification algorithms thereto; and a computerized maintenance management system (CMMS) that produces at least one of orders and requests for service and parts responsive to receiving the industrial machine service recommendations.

2. The industrial machine predictive maintenance system of claim 1, further comprising: a service and delivery coordination facility that receives and processes information regarding services performed on industrial machines responsive to the at least one of orders and requests for service and parts, thereby validating the services performed while producing a ledger of service activity and results for individual industrial machines.

3. The industrial machine predictive maintenance system of claim 2, wherein the ledger uses a blockchain structure to track records of transactions for each of the at least one of the orders and the requests for service and parts, wherein each record is stored as a block in the blockchain structure.

4. The industrial machine predictive maintenance system of claim 3, wherein the CMMS generates subsequent blocks of the ledger by combining data from at least one of shipment readiness, installation, operational sensor data, service events, parts orders, service orders, or diagnostic activity with a hash of a most recently generated block in the ledger.

5. The industrial machine predictive maintenance system of claim 1, further comprising: a self-organization system that controls movements of the one or more mobile data collectors within the industrial environment.

6. The industrial machine predictive maintenance system of claim 5, wherein the self-organization system transmits requests for the health monitoring data to the one or more mobile data collectors, wherein the mobile data collectors transmit the health monitoring data to the self-organization system responsive to the requests, wherein the self-organization transmits the health monitoring data to the industrial machine predictive maintenance facility.

7. The industrial machine predictive maintenance system of claim 1, further comprising: a data collection router that receives the health monitoring data from the one or more mobile data collectors when the mobile data collectors are in near proximity to the data collection router, wherein the data collection router transmits the health monitoring data to the industrial machine predictive maintenance facility.

8. The industrial machine predictive maintenance system of claim 7, wherein the one or more mobile data collectors push the health monitoring data to the data collection router.

9. The industrial machine predictive maintenance system of claim 7, wherein the data collection router pulls the health monitoring data from the one or more mobile data collectors.

10. The industrial machine predictive maintenance system of claim 7, further comprising: a self-organization system that controls movements of the one or more mobile data collectors within the industrial environment.

11. The industrial machine predictive maintenance system of claim 10, wherein the self-organization system controls communications of the health monitoring data from the one or more mobile data collectors to the data collection router.

12. The industrial machine predictive maintenance system of claim 1, wherein each mobile data collector of the one or more mobile data collectors is one of a mobile robot including one or more integrated sensors, a mobile robot including one or more coupled sensors, a mobile vehicle with one or more integrated sensors, or a mobile vehicle with one or more coupled sensors.

13. The industrial machine predictive maintenance system of claim 1, wherein the industrial machine predictive maintenance facility produces the industrial machine service recommendations based on severity units calculated for the health monitoring data.

14. A system comprising: a plurality of wearable devices integrated within an industrial uniform, each wearable device of the industrial uniform comprising one or more sensors that collect measurements from industrial machines located in an industrial environment, the measurements representative of conditions of the industrial machines; an industrial machine predictive maintenance facility that produces industrial machine service recommendations based on the measurements by applying machine fault detection and classification algorithms thereto; and a computerized maintenance management system (CMMS) that produces at least one of orders and requests for service and parts responsive to receiving the industrial machine service recommendations.

15. The system of claim 14, further comprising: a service and delivery coordination facility that receives and processes information regarding services performed on industrial machines responsive to the at least one of orders and requests for service and parts, thereby validating the services performed while producing a ledger of service activity and results for individual industrial machines.

16. The system of claim 15, wherein the ledger uses a blockchain structure to track records of transactions for each of the at least one of the orders and the requests for service and parts, wherein each record is stored as a block in the blockchain structure.

17. The system of claim 16, wherein the CMMS generates subsequent blocks of the ledger by combining data from at least one of shipment readiness, installation, operational sensor data, service events, parts orders, service orders, or diagnostic activity with a hash of a most recently generated block in the ledger.

18. The system of claim 14, wherein the one or more sensors of a first wearable device of the industrial uniform includes a sensor configured to collect vibration measurements from at least one of the industrial machines.

19. The system of claim 14, wherein the one or more sensors of a second wearable device of the industrial uniform includes a sensor configured to collect temperature measurements from at least one of the industrial machines.

20. The system of claim 14, wherein the one or more sensors of a first wearable device of the industrial uniform includes a sensor configured to collect electrical measurements from at least one of the industrial machines.

21. The system of claim 14, wherein the one or more sensors of a first wearable device of the industrial uniform includes a sensor configured to collect magnetic measurements from at least one of the industrial machines.

22. The system of claim 14, wherein the one or more sensors of a first wearable device of the industrial uniform includes a sensor configured to collect sound measurements from at least one of the industrial machines.

23. The system of claim 14, wherein a first wearable device of the industrial uniform is an article of clothing and a second wearable device of the industrial uniform is an accessory article.

24. The system of claim 14, further comprising: a collective processing mind that controls the collection of measurements of the one or more industrial machines by the plurality of wearable devices.

25. The system of claim 24, wherein the collective processing mind transmits a first command to a wearable device of the industrial uniform to cause the one or more sensors of the wearable device to collect the measurements of the one or more industrial machines, wherein the collective processing mind transmits a second command to the wearable device to cause the wearable device to transmit the measurements to the collective processing mind.

26. The system of claim 14, wherein the industrial machine predictive maintenance facility produces the industrial machine service recommendations based on severity units calculated for the measurements.