Method for predicting machine or process faults and automated system for implementing same
First Claim
1. A method of predicting the occurrence an event on a machine or process comprising the steps of:
- receiving a first set of historical operating data from said machine or process, said first set of historical operating data including at least one occurrence of the significant event to be predicted;
creating a predictive model based on the first set of historical operating data such that when the predictive model is applied to future sets of historical operating data the predictive model will predict whether said significant event will occur within a specified prediction window;
receiving a second set of historical operating data from said machine, said second set of historical operating data covering a data collection period preceding the prediction window;
applying the predictive model to the second set of historical operating data to predict whether the significant event will occur during the prediction window.
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Abstract
A method for developing machine or process specific predictions of error codes and machine or processes events associated with the operation of one or more machines or processes is provided. The method involves a data set evaluation phase and a monitoring phase. The data set evaluation phase requires an analysis of historical operating data from said one or more machines or processes to identify significant precursor patterns associated with the occurrence of the error codes or events. The method next involves developing predictive models based on the application of one or more statistical tools and pattern recognition techniques whereby future occurrences of the error codes may be predicted within a defined time window from an analysis of the occurrences of significant precursor events within a data collection time window which precedes the prediction time window. Operating data, including the occurrences of the significant precursor events, are then collected during the data collection time window. The predictive model is applied to the data collected during the data collection window to generate predictions of the occurrence of the error codes within a predefined prediction time window.
201 Citations
32 Claims
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1. A method of predicting the occurrence an event on a machine or process comprising the steps of:
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receiving a first set of historical operating data from said machine or process, said first set of historical operating data including at least one occurrence of the significant event to be predicted;
creating a predictive model based on the first set of historical operating data such that when the predictive model is applied to future sets of historical operating data the predictive model will predict whether said significant event will occur within a specified prediction window;
receiving a second set of historical operating data from said machine, said second set of historical operating data covering a data collection period preceding the prediction window;
applying the predictive model to the second set of historical operating data to predict whether the significant event will occur during the prediction window. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A process for predicting the occurrence of one or more machine error codes associated with the operation of one or more machines or processes, the method comprising the steps of:
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analyzing historical operating data from said one or more machines or processes to identify significant precursor events associated with the occurrence of each said error code;
developing predictive models for each error code based on the application of one or more statistical tools and pattern recognition techniques whereby future occurrences of said error codes may be predicted within a defined prediction time window from an analysis of the occurrences of said significant precursor events within a data collection time window preceding the prediction time window;
collecting operating data, including the occurrence of said significant precursor events, during the data collection time window; and
applying the predictive models to the data collected to generate predictions of the occurrence of said error codes on said one or more machines or processes within the prediction time window. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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20. A method of performing predictive maintenance on a machine or process, comprising the steps of:
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receiving historical operating data from the machine or process, said historical operating data including the occurrence of significant operating events;
analyzing the historical operating data to determine whether foreknowledge of the future occurrence of a significant operating event has value; and
implementing a program for predicting the occurrence of those significant events for which it has been determined that having foreknowledge of the future occurrence of the event has value within a predefined prediction window based on an historical operating data set gathered during a data collection window preceding the prediction window.
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Specification