Diagnostic systems and methods for predictive condition monitoring
First Claim
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1. A monitoring apparatus for diagnosing faults in a system, comprising:
- a reference data store containing failure mode identification data and associated system data indicative of behavior of said system in the failure mode; and
a similarity engine responsive to monitored system data indicative of monitored behavior of said system, for generating at least one similarity value for a comparison of the monitored data to said failure mode associated system data, as a diagnostic indication of said failure mode.
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Abstract
A system for empirically diagnosing a condition of a monitored system. Estimates of monitored parameters from a model of the system provide residual values that can be analyzed for failure mode signature recognition. Residual values can also be tested for alert (non-zero) conditions, and patterns of alerts thus generated are analyzed for failure mode signature patterns. The system employs a similarity operator for signature recognition and also for parameter estimation. Failure modes are empirically determined, and precursor data is automatically analyzed to determine differentiable signatures for failure modes.
167 Citations
62 Claims
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1. A monitoring apparatus for diagnosing faults in a system, comprising:
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a reference data store containing failure mode identification data and associated system data indicative of behavior of said system in the failure mode; and
a similarity engine responsive to monitored system data indicative of monitored behavior of said system, for generating at least one similarity value for a comparison of the monitored data to said failure mode associated system data, as a diagnostic indication of said failure mode. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for diagnosing faults in a monitored system, comprising the steps of:
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acquiring monitored system data indicative of monitored behavior of said system; and
comparing for similarity the monitored system data to reference system data associated with a failure mode to generate a similarity value as a diagnostic indication of said failure mode. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17)
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18. A monitoring apparatus for diagnosing faults in a system, comprising:
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a non-parametric model responsive to monitored parameter data from said system for generating estimates of the monitored parameter data;
an alert module disposed to produce parameter alerts in response to a comparison of said estimates to said monitored data; and
a failure identification module for identifying an impending failure mode in said system by matching said parameter alerts with at least one reference alert pattern associated with said failure mode. - View Dependent Claims (19, 20, 21, 22)
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23. A method for diagnosing faults in a monitored system, comprising the steps of:
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comparing for similarity monitored parameter data from said system to reference parameter data characteristic of known behavior of said system;
generating estimates of the monitored parameter data based on the similarity comparison;
generating alerts in response to a comparison of said estimates to said monitored data; and
identifying an impending failure mode in said system by matching said parameter alerts with at least one reference alert pattern associated with said failure mode. - View Dependent Claims (24, 25)
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26. A monitoring apparatus for diagnosing faults in a system, comprising:
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a similarity engine responsive to monitored parameter data from said system for generating estimates of the monitored parameter data;
means for differencing the estimates and the monitored data to generate residual data; and
means for recognizing an impending failure mode by comparing for similarity said residual data to reference residual data associated with the failure mode. - View Dependent Claims (27, 28, 29, 30, 31)
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32. A method for diagnosing faults in a monitored system, comprising the steps of:
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comparing for similarity monitored parameter data from said system to reference parameter data characteristic of known behavior of said system;
generating estimates of the monitored parameter data based on the similarity comparison;
differencing the estimates and the monitored data to generate residual data; and
comparing for similarity the residual data to reference residual data associated with a failure mode, as a diagnostic indication of said failure mode. - View Dependent Claims (33, 34)
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35. A computer program product for diagnosing faults in a monitored system, comprising:
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a residual testing program module for generating alerts in response to residual signals characterizing behavior of said system; and
a fault pattern detection program module disposed to receive said alerts and indicate a fault in said system upon matching the alerts to a reference pattern associated with said fault. - View Dependent Claims (36, 37, 38, 39)
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40. A method for forming a diagnostic monitoring system for a machine, comprising the steps of:
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instrumenting a plurality of like machines with sensors;
operating said plurality of machines and collecting operational sensor data characterizing operation;
autopsying each of said plurality of machines upon failure to determine a failure mode, and storing the failure modes for use in the diagnostic monitoring system;
selecting a failure precursor portion of said operational sensor data collected for a selected interval prior to failure of each machine; and
distilling each said failure precursor data portion into at least one failure signature data set and associating each set with a corresponding failure mode. - View Dependent Claims (41, 42, 43)
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44. A diagnostic monitoring apparatus for a sensor-instrumented system selected from a process and a machine, comprising:
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an operational model module for modeling said system and generating estimates for said sensors in response to receiving actual values of said sensors;
a differencing module for generating residual signals from said estimates and said actual values;
a reference library for storing failure modes and associated residual data values; and
a failure mode recognition engine disposed to compare generated residual signals with said residual data values to select and output a recognized failure mode for said system. - View Dependent Claims (45, 46)
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47. A diagnostic monitoring apparatus for a sensor-instrumented system selected from a process and a machine, comprising:
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an operational model module for modeling said system and generating estimates for said sensors in response to receiving actual values of said sensors;
a differencing module for generating residual signals from said estimates and said actual values;
a testing module disposed to receive said residual signals and generate alerts in response thereto;
a reference library for storing failure modes and associated alert signatures; and
a failure mode recognition engine disposed to compare generated alerts with said alert signatures to select and output a recognized failure mode for said system.
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48. A diagnostic monitoring apparatus for a sensor-instrumented system selected from a process and a machine, comprising:
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sensor input for receiving current sensor data from said system in operation;
an information processor for collecting the current sensor data from the sensor input at selected time snapshots associated with the signals at the sensor input being indicative of identified states of the monitored process;
a reference library for storing failure modes and associated snapshots of sensor data from said system;
a failure mode recognition engine disposed to compare current sensor data with said snapshots to select and output a recognized failure mode for said system. - View Dependent Claims (49, 50, 51, 52, 54, 55, 56, 57, 58, 59, 60, 61, 62)
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53. A diagnostic monitoring apparatus for a sensor-instrumented system selected from a process and a machine, comprising:
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a sensor input receiver for receiving current sensor data from conveyed signals acquired at selected time snapshots as inputs indicative of said system in operation;
a memory for storing empirical model estimates of parameter values in response to collected signals indicative of the monitored process corresponding to a universe of identified states of the monitored process;
a reference library for storing failure modes and associated snapshots of sensor data from said system;
an information processor for collecting the conveyed signals acquired at selected time snapshots as inputs indicative of identified states of the monitored process;
a similarity operator implemented within said information processor operable on the acquired time snapshots and the parameter values from said memory for generating an expected state vector responsive to said similarity operator; and
a failure mode recognition engine disposed to compare current sensor data with said snapshots to select and output a recognized failure mode for said system.
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Specification