METHODS AND SYSTEMS FOR DETECTING OPERATING CONDITIONS OF AN INDUSTRIAL MACHINE USING THE INDUSTRIAL INTERNET OF THINGS

Abstract

Systems and methods for detecting operating characteristics of an industrial machine are disclosed. The detecting can include generating one or more image data sets using raw data captured by one or more data capture devices and identifying one or more values corresponding to a portion of the industrial machine within a point of interest represented by the one or more image data sets. The one or more values can be compared to corresponding predicted values and a variance data set can be generated based on the comparison of the one or more values and the corresponding predicted values. An operating characteristic of the industrial machine can be identified based on the variance data and data indicating a detection of the operating characteristic can be generated.

Claims

1. A method for detecting operating characteristics of an industrial machine, comprising: generating one or more image data sets using raw data captured by one or more data capture devices; identifying one or more values corresponding to a portion of the industrial machine within a point of interest represented by the one or more image data sets; comparing the one or more values to corresponding predicted values; generating a variance data set based on the comparison of the one or more values and the corresponding predicted values; identifying an operating characteristic of the industrial machine based on the variance data; and generating data indicating a detection of the operating characteristic.

2. The method of claim 1, wherein the operating characteristic represents a possible or present issue relating to an operation of the industrial machine, the method further comprising: identifying a maintenance action to perform responsive to identifying the operating characteristic, the maintenance action representing action which may be taken to prevent or resolve the possible or present issue relating to the operation of the industrial machine.

3. The method of claim 2, wherein identifying the maintenance action to perform responsive to identifying the operating characteristic comprises: using predictive maintenance to predict the possible or present issue based on the operating characteristic.

4. The method of claim 2, further comprising: generating a signal indicative of the maintenance action; and transmitting the signal to a server to execute the maintenance action.

5. The method of claim 2, further comprising: generating a signal indicative of the maintenance action; and transmitting the signal to a mobile robot to cause the mobile robot to perform the maintenance action.

6. The method of claim 2, wherein using the predictive maintenance to predict the possible or present issue based on the operating characteristic comprises: determining a severity of the possible or present issue based on the operating characteristic, the severity representing an impact of the operating characteristic on the industrial machine, the severity indicating a priority for resolving the possible or present issue.

7. The method of claim 1, wherein the raw data is captured responsive to instructions received from a wearable device worn by a user in an environment of the industrial machine, the method further comprising: indicating to the user to perform the maintenance action by communicating a signal indicative of the maintenance action to the wearable device.

8. The method of claim 1, wherein the raw data is captured responsive to instructions received from a mobile data collector located in an environment of the industrial machine, the method further comprising: initiating the maintenance action by communicating a signal indicative of the maintenance action to the mobile data collector.

9. The method of claim 8, wherein the mobile data collector is a mobile robot.

10. The method of claim 1, wherein at least one of the one or more data capture devices is a mobile device including a camera, the method further comprising: causing the camera of the mobile device to capture the raw data; and transmitting, from the mobile device, a signal including the raw data to a computer vision system used to generate the one or more image data sets.

11. The method of claim 1, wherein the operating characteristic includes a vibration of a component of the industrial machine.

12. The method of claim 1, wherein the operating characteristic includes a shape of a component of the industrial machine or a size of a component of the industrial machine.

13. The method of claim 1, wherein the operating characteristic includes a deflection of a component of the industrial machine.

14. The method of claim 1, wherein the operating characteristic includes an electromagnetic emission of a component of the industrial machine.

15. The method of claim 1, wherein the operating characteristic includes at least one of: (i) a temperature of a component of the industrial machine, (ii) a temperature of a gas within a component of the industrial machine, (iii) a temperature of a liquid within a component of the industrial machine, and (iv) a temperature of a solid within a component of the industrial machine.

16. The method of claim 1, wherein the operating characteristic includes at least one of: (i) a pressure within a component of the industrial machine, (ii) a pressure of a gas within a component of the industrial machine, and (iii) a pressure of a liquid within a component of the industrial machine.

17. The method of claim 1, wherein the operating characteristic includes at least one of: (i) a density of a gas within a component of the industrial machine, (ii) a density of a liquid within a component of the industrial machine, and (iii) a density of a solid within a component of the industrial machine.

18. The method of claim 1, wherein the operating characteristic includes a density of a component manufactured by the industrial machine.

19. The method of claim 18, wherein the component includes a part for a vehicle.

20. The method of claim 18, wherein the component includes a part for a bike.

21. The method of claim 18, wherein the component includes a bike chain.

22. The method of claim 18, wherein the component includes a gasket.

23. The method of claim 18, wherein the component includes at least one of: (i) a fastener, (ii) a part for a screw, and (iii) a part for a bolt.

24. The method of claim 18, wherein the component includes a part for a printed circuit board.

25. The method of claim 18, wherein the component includes at least one of: (i) a part for a capacitor, (ii) a part for a resistor, and (iii) a part for an inductor.

26. The method of claim 1, wherein the operating characteristic includes at least one of: (i) a chemical structure of a gas within a component of the industrial machine, (ii) a chemical structure of a liquid within a component of the industrial machine, and (iii) a chemical structure of a solid within a component of the industrial machine.

27. The method of claim 1, wherein the operating characteristic includes a chemical structure of a component manufactured by the industrial machine.

28. The method of claim 27, wherein the component includes a part for a vehicle.

29. The method of claim 27, wherein the component includes a part for a bike.

30. The method of claim 27, wherein the component includes a bike chain.

31. The method of claim 27, wherein the component includes a gasket.

32. The method of claim 27, wherein the component includes at least one of: (i) a fastener, (ii) a part for a screw, and (iii) a part for a bolt.

33. The method of claim 27, wherein the component includes a part for a printed circuit board.

34. The method of claim 27, wherein the component includes at least one of: (i) a part for a capacitor, (ii) a part for a resistor, and (iii) a part for an inductor.

35. The method of claim 1, wherein the data capture device includes an image capture device.

36. The method of claim 1, wherein the data capture device includes a camera.

37. The method of claim 1, wherein the data capture device includes data measurement device.

38. The method of claim 1, wherein the data capture device includes a sensor.

39. The method of claim 1, wherein the data capture device includes a full spectrum camera.

40. The method of claim 1, wherein the data capture device includes radiation imaging device.

41. The method of claim 1, wherein the data capture device includes an X-ray imaging device.

42. The method of claim 1, wherein the data capture device includes a non-visible light data capture device or a visible light data capture device.

43. The method of claim 1, wherein the data capture device includes sonic data capture device.

44. The method of claim 1, wherein the data capture device includes an image capture device.

45. The method of claim 1, wherein the data capture device includes light imaging, detection, and ranging device.

46. The method of claim 1, wherein the data capture device includes point cloud data capture device.

47. The method of claim 1, wherein the data capture device includes an infrared inspection device.

48. The method of claim 1, wherein the data capture device includes an image capture device.

49. The method of claim 1, wherein the data capture device includes at least one of: (i) a pressure sensor, (ii) a temperature sensor, and (iii) a chemical sensor.

50. The method of claim 1, wherein the data capture device includes a stand-alone device.

51. The method of claim 1, wherein the data capture device includes at least one of: (i) a mobile device, (ii) a smart phone, and (iii) a tablet.

52. The method of claim 1, wherein the raw data includes raw image data.

53. The method of claim 1, wherein the raw data includes raw measurement data.

54. The method of claim 1, wherein the portion of the industrial machine within the point of interest includes a component of the industrial machine.

55. The method of claim 1, wherein the portion of the industrial machine within the point of interest includes a belt of the industrial machine.

56. The method of claim 1, wherein the portion of the industrial machine within the point of interest includes a component manufactured by the industrial machine.

57. The method of claim 1, wherein the portion of the industrial machine within the point of interest includes a bike chain manufactured by the industrial machine.