Predictive monitoring system and method

• US 10,330,524 B2
• Filed: 02/16/2016
• Issued: 06/25/2019
• Est. Priority Date: 02/16/2016
• Status: Active Grant

• Current Assignee: Ballard Technology, Inc. (Astronics Corporation)
• Original Assignee: Inflight Warning Systems, Inc.
• Inventors: Barclay, Joseph, Kirby, Brian
• Primary Examiner(s): Riad, Amine
• Application Number:
  US15/044,473
• Publication Number:
  US 20170235620A1
• Time in Patent Office: 1,225 Days
• Field of Search: 714 472
• CPC Class Codes: G01H 3/00 Measuring characteristics of vibrations by using a detector in a fluid G01H7/00, G01H9/00, G01H11/00 take precedence
• CPC Class Codes: G05B 23/0262 Confirmation of fault detection, e.g. extra checks to confirm that a failure has indeed occurred
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: G05B 23/0291 Switching into safety or degraded mode, e.g. protection and supervision after failure

Abstract

A system and method is disclosed which monitors factors in order to prevent impending component failure within a mechanical system, such as an aircraft. The monitoring system monitors the health and condition of system components, and utilizes proprietary algorithms to predict impending failures in monitored components before failure occurs. The system can shut down a component, send an alert, or adjust component thresholds as required.

Claims

1. A system for monitoring a complex system, comprising:

a plurality of data recorders joined to a plurality of monitored components within the monitored system, and said data recorders directly measure operating characteristics of the monitored components; and

a monitor in digital communication with the plurality of data recorders, such that the monitor receives real-time data from said plurality of data recorders, the monitor includes computing hardware to process said data and to execute prescribed operations that include

(a) determining pre-failure conditions for the plurality of monitored components within the monitored system, via

(1) providing inputs pertaining to one or more factors of the monitored system, said inputs representing signatures of both serviceable and non-serviceable components,

(2) performing a moving-range analysis on every combination of factors so as to generate one or more filters, wherein each filter represents a specific combination of factors and the associated range of the measured operating characteristics for a given component,

(3) developing distribution plots for each filter,

(4) developing a consistent pre-failure condition path for the component, and

(5) selecting a filter from the one or more filters having the highest probability of catching all unserviceable units and eliminating false positive indications;

(b) detecting a monitored component that is designated as a non-essential component and that satisfies one or more of said pre-failure conditions, such that the detected component is in imminent failure; and

(c) sending a command to a respective data recorder to deactivate the corresponding detected component that is in imminent failure.

2. The system as defined in claim 1, wherein one monitor device is connected to a plurality of data recorder devices via wired or wireless means, so as to facilitate two-way communications with the data recorders.

3. The system as defined in claim 1, wherein the system is implemented to monitor systems on an airplane.

4. The system as defined in claim 1, wherein the monitor is powered by local electrical input.

5. The system as defined in claim 1, wherein the data recorders include one or more of the following:

a vibration data recorder, a temperature data recorder, and an electrical data recorder.

6. The system as defined in claim 1, wherein Z-scores are developed to determine the consistent pre-failure condition path for the component, and the filter with the highest Z-score is selected.