Failure mode ranking in an asset management system

• US 10,489,752 B2
• Filed: 08/26/2016
• Issued: 11/26/2019
• Est. Priority Date: 08/26/2016
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Korsedal, IV, John Robert, Hein, Carlos Andres, Higgins, Christopher D., Lindenmuth, Marc Gavin, Dill, Molli Anne, Zhao, Yan
• Primary Examiner(s): Dalbo, Michael J
• Application Number:
  US15/248,036
• Publication Number:
  US 20180060832A1
• Time in Patent Office: 1,187 Days
• CPC Class Codes: G01M 99/005 Testing of complete machines, e.g. washing-machines or mobile phones testing of machine parts G01M13/00; testing of electric apparatus or components G01R31/50
• CPC Class Codes: G05B 23/0278 Qualitative, e.g. if-then rules; Fuzzy logic; Lookup tables; Symptomatic search; FMEA
• 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: G06Q 10/0635 Risk analysis of enterprise or organisation activities
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance

Abstract

This disclosure provides systems for using failure mode ranking in an asset management system to generate asset maintenance outputs. Operational data, failure mode models, and configuration data for an asset, such as a complex electromechanical system, are related to failure prevention analytics configurations through failure mode rankings to enable the asset management system to reduce a future ranking of potential failure modes by changing the present configuration of the asset to include a recommended failure prevention analytics configuration.

Claims

1. A system comprising:

a plurality of sensing devices configured to generate operational data indicative of a plurality of operating parameters for an asset; and

a computing system in communication with the plurality of sensing devices for receiving the operational data, the computing system including;

a plurality of failure mode models stored in at least one data repository accessible to the computing system and describing a plurality of potential failure modes of a class of assets including the asset;

asset configuration data stored in the at least one data repository accessible to the computing system and describing at least a present configuration of the asset;

an analytics library stored in the at least one data repository accessible to the computing system and providing a plurality of failure prevention analytics configurations, at least one of the plurality of failure prevention analytics configurations describing detection and prevention resources associated with at least one of the described plurality of potential failure modes of the class of assets including the asset;

a failure mode ranking system accessed by the computing system and using the operational data, the asset configuration data, and the plurality of failure prevention analytics configurations provided by the analytics library to rank the plurality of potential failure modes by a severity of failure, the ranked plurality of potential failure modes including the at least one associated failure prevention analytics configuration;

relationship data including a plurality of relationships among the operational data, the plurality of failure mode models, the asset configuration data, the plurality of failure prevention analytics configurations, and the failure mode ranking system; and

an asset maintenance output generated by the computing system using the failure mode ranking system to reduce a future ranking of at least one of the plurality of potential failure modes by changing the present configuration of the asset to include a recommended failure prevention analytics configuration.

2. The system of claim 1, wherein the plurality of failure prevention analytics configurations includes a plurality of lifing analytics.

3. The system of claim 1, wherein the plurality of failure prevention analytics configurations includes a plurality of anomaly detection analytics.

4. The system of claim 1, wherein the failure mode ranking system includes at least one prevention control field and at least one detection control field based on the present configuration of the asset.

5. The system of claim 4, wherein the failure mode ranking system uses an available prevention resource not included in the present configuration of the asset and the at least one associated failure prevention analytics configuration to rank the plurality of potential failure modes and the asset maintenance output includes a recommendation to add the available prevention resource to the present configuration of the asset.

6. The system of claim 4, wherein the failure mode ranking system uses an available detection resource not included in the present configuration of the asset and the at least one associated failure prevention analytics configuration to rank the plurality of potential failure modes and the asset maintenance output includes a recommendation to add the available detection resource to the present configuration of the asset.

7. The system of claim 1, further comprising a relational database map between the plurality of failure mode models and the plurality of failure prevention analytics configurations.

8. The system of claim 1, further comprising:

a configuration options library stored in the at least one data repository accessible to the computing system and including a plurality of sensor options for the class of assets including the asset; and

a relational database map between the plurality of sensor options and the plurality of failure prevention analytics configurations.

9. The system of claim 1, further comprising a recommendation tracking system accessed by the computing system and using the asset management output and a maintenance log for the asset to determine when the present configuration of the asset is changed to include the recommended failure prevention analytics configuration.

10. A computing system comprising:

a relational database structure including;

a plurality of operational data elements stored in at least one data repository accessible to the computing system and indicative of a plurality of operating parameters for an asset;

a plurality of failure mode model elements stored in at least one data repository accessible to the computing system and describing a plurality of potential failure modes of a class of assets including the asset;

a plurality of asset configuration data elements stored in at least one data repository accessible to the computing system and describing at least a present configuration of the asset;

a plurality of failure prevention analytics configuration elements stored in the at least one data repository accessible to the computing system and describing detection and prevention resources associated with the plurality of potential failure modes of the class of assets including the asset;

a plurality of failure mode ranking elements stored in at least one data repository accessible to the computing system and ranking the plurality of potential failure modes by a severity of failure, the ranked plurality of potential failure modes includes the associated failure prevention analytics configuration elements; and

a plurality of relationships among the plurality of operational data elements, the plurality of failure mode model elements, the plurality of asset configuration data elements, the plurality of failure prevention analytics configuration elements, and the plurality of failure mode ranking elements; and

an asset management system implemented by the computing system and using the relational database structure to generate an asset maintenance output reducing a future ranking of at least one of the plurality of potential failure modes by changing the present configuration of the asset to include a recommended failure prevention analytics configuration.

11. The computing system of claim 10, wherein the plurality of failure prevention analytics configuration elements includes a plurality of lifing analytics.

12. The computing system of claim 10, wherein the plurality of failure prevention analytics configuration elements includes a plurality of anomaly detection analytics.

13. The computing system of claim 10, wherein the plurality of failure mode ranking elements includes at least one prevention control field and at least one detection control field related to at least one of the plurality of asset configuration data elements representing the present configuration of the asset.

14. The computing system of claim 13, wherein the asset management system uses an available prevention resource not included in the present configuration of the asset and the associated failure prevention analytics configuration element including the available prevention resource to rank the plurality of potential failure modes and the asset maintenance output includes a recommendation to add the available prevention resource to the present configuration of the asset.

15. The computing system of claim 13, wherein the asset management system uses an available detection resource not included in the present configuration of the asset and the associated failure prevention analytics configuration element including the available prevention resource to rank the plurality of potential failure modes and the asset maintenance output includes a recommendation to add the available detection resource to the present configuration of the asset.

16. The computing system of claim 10, wherein the plurality of relationships include a relational database map between the plurality of failure mode models and the plurality of failure prevention analytics configurations.

17. The computing system of claim 10, wherein the relational database structure further includes a plurality of sensor option elements stored in the at least one data repository accessible to the computing system and wherein the plurality of relationships include a relational database map between the plurality of sensor option elements and the plurality of failure prevention analytics configuration elements.

18. The computing system of claim 10, wherein the asset management system further comprises a recommendation tracking system using the asset management output and a maintenance log for the asset to determine when the present configuration of the asset is changed to include the recommended failure prevention analytics configuration.

19. An asset management system operating in a memory of a computing system, the asset management system comprising:

an asset operations receiving system configured to receive operational data indicative of a plurality of operating parameters for an asset;

an asset failure mode model system configured to access a plurality of failure mode models stored in at least one data repository accessible to the computing system and describing a plurality of potential failure modes of a class of assets including the asset;

a present configuration system configured to access asset configuration data stored in the at least one data repository accessible to the computing system and describing at least a present configuration of the asset;

an analytics system including an analytics library stored in the at least one data repository accessible to the computing system and providing a plurality of failure prevention analytics configurations, at least one of the plurality of failure prevention analytics configurations describing detection and prevention resources associated with at least one of the described plurality of potential failure modes of the class of assets including the asset;

a failure mode ranking system configured to access the plurality of failure prevention analytics configurations associated with the plurality of potential failure and use the operational data, the asset configuration data, and the plurality of failure prevention analytics configurations to rank the plurality of potential failure modes by a severity of failure, the ranked plurality of potential failure modes including the associated failure prevention analytics configurations;

a relationship system including relationship data stored in the at least one data repository accessible to the computing system, the relationship data including a plurality of relationships among the operational data, the plurality of failure mode models, the asset configuration data, the plurality of failure prevention analytics configurations, and the failure mode ranking system; and

wherein the failure mode ranking system generates an asset maintenance output to reduce a future ranking of at least one of the plurality of potential failure modes by changing the present configuration of the asset to include a recommended failure prevention analytics configuration.

20. The asset management system of claim 19, wherein the failure prevention analytics configurations are related to a plurality of sensor options stored in the at least one data repository accessible to the computing system, and the asset management system further comprises a relational database map between the plurality of sensor options and the plurality of failure prevention analytics configurations and the recommended failure prevention analytics configuration includes addition of at least one sensor to the asset.