Automation of imaging and dynamic signal analyses

• US 20060017821A1
• Filed: 07/26/2004
• Published: 01/26/2006
• Est. Priority Date: 07/26/2004
• Status: Active Grant

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company)
• Inventors: Rich, Michael D., Hayzen, Anthony J., Garvey, Raymond E. III, Granger, Mark
• Granted Patent: US 7,561,200 B2
• Time in Patent Office: Days
• US Class Current: 348/231.300
• CPC Class Codes: G01H 1/12 of longitudinal or not specified vibrations
• CPC Class Codes: G01H 17/00 Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups see provisionally also G01H1/00
• CPC Class Codes: H04N 17/002 for television cameras
• CPC Class Codes: H04N 5/765 Interface circuits between an apparatus for recording and another apparatus
• CPC Class Codes: H04N 5/77 between a recording apparatus and a television camera
• CPC Class Codes: H04N 5/775 between a recording apparatus and a television receiver

Abstract

A method and apparatus for inspecting equipment using focal plane array imaging sensor data and dynamic sensor data. Methods involve capturing focal plane array imaging sensor data using a focal plane array imaging sensor such as an infrared camera or a visible camera, or acquiring imaging sensor data from an electronic data storage source, and involve capturing dynamic sensor data, such as vibration or ultrasonic data using a dynamic sensor such as an accelerometer or ultrasound system. Methods also provide for analyzing imaging and dynamic sensor data using such techniques as thermography and fast fourier transformation. Apparatuses include a portable instrument with sensor interfaces for collecting imaging sensor data and dynamic sensor data. A sensor suite is provided that includes vibration sensor, sonic sensors, ultrasonic sensors, oil sensors, flux sensors and current sensors. A base station is included to collect and analyze data from one or more portable instruments.

Claims

1. A portable instrument for inspecting equipment, comprising:

a first sensor interface for a focal plane array imaging sensor, the first sensor interface including electro-mechanics configured to receive imaging sensor data;

a second sensor interface for a dynamic sensor, the second sensor interface including electro-mechanics configured to receive dynamic sensor data;

digital memory that stores an operating system and application instructions and a dataset, and

a processor that runs the operating system and is operatively connected to the digital memory and operatively connected to the first sensor interface and is operatively connected to the second sensor interface, and where the processor is configured to use at least a portion of the application instructions for recording in the dataset at least a portion of imaging sensor data and for recording in the dataset at least a portion of dynamic sensor data, and where the processor is further configured to use at least a portion of the application instructions to operate on the imaging sensor data and to derive at least one dynamic indication of equipment health;

a display that presents information; and

a user interface that in cooperation with the processor controls what information is presented on the display.

2. The instrument of claim 1 wherein the processor is further configured to use at least a portion of the application instructions for establishing an association data element.

3. The instrument of claim 1 wherein the processor is further configured to use at least a portion of the application instructions for deriving at least one imagery indication of equipment health.

4. The instrument of claim 1 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array infrared imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a vibration sensor.

5. The instrument of claim 1 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array visible imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a vibration sensor.

6. The instrument of claim 1 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array infrared imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a sonic sensor.

7. The instrument of claim 1 wherein the display presents an imaging analysis function and a dynamic signal analysis function using at least one window.

8. The instrument of claim 1 wherein the instrument further comprises a wireless transmitter controlled by the processor.

9. The instrument of claim 1 wherein the instrument further comprises a sound recorder and a microphone connected to the sound recorder, the sound recorder being controlled by the processor in cooperation with the user interface.

10. The instrument of claim 1 wherein the instrument further comprises a third sensor interface for a static sensor, the third sensor interface for a static sensor comprising electro-mechanics configured to receive static sensor data.

11. The instrument of claim 1 wherein at least a portion of the application instructions is configured for analyzing waveforms to at least in part derive the at least one dynamic indication of equipment health.

12. A portable apparatus for inspecting equipment, comprising:

a first sensor interface for a focal plane array imaging sensor, the first sensor interface including electro-mechanics configured to receive imaging sensor data;

a second sensor interface for a dynamic sensor, the second sensor including electro-mechanics configured to receive dynamic sensor data;

a processor operatively connected to the first sensor interface and operatively connected to the second sensor interface and configured with an application instruction for analyzing the dynamic sensor data and for deriving at least one dynamic indication of equipment health;

a display that presents information; and

a user interface that in cooperation with the processor controls what information is presented on the display;

a focal plane array imaging sensor that is operatively connected to the first sensor interface for sending imaging sensor data to the first sensor interface; and

a dynamic sensor that is operatively connected to the second sensor interface for sending dynamic data to the second sensor interface.

13. The apparatus of claim 12 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array infrared imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a vibration sensor and the imaging sensor comprises a focal plane array infrared imaging sensor and the dynamic sensor comprises a vibration sensor.

14. The apparatus of claim 12 wherein at least one sensor interface (a) comprises a data acquisition board and (b) is housed in a portable platform with the processor, the display, and the user interface.

15. The apparatus of claim 12 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane visible imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a vibration sensor and the imaging sensor comprises a focal plane visible imager and the dynamic sensor comprises a vibration sensor.

16. The apparatus of claim 12 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array infrared imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a sonic sensor and the imaging sensor comprises a focal plane array infrared imaging sensor and the dynamic sensor comprises a sonic sensor.

17. The apparatus of claim 12 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for an uncooled focal plane array infrared imager and the imaging sensor comprises an uncooled focal plane array infrared imager that transmits infrared imaging sensor data to the first sensor interface.

18. The apparatus of claim 17 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for an uncooled focal plane array infrared imager having an imaging sensor array of at least 16×

16 pixels and the uncooled focal plane array infrared imager comprises an imaging sensor array of at least 16×

16 pixels.

19. The apparatus of claim 12 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array visible and focal plane array infrared imaging sensor and the imaging sensor comprises a focal plane array visible and focal plane array infrared imager and the dynamic sensor comprises a vibration sensor.

20. The apparatus of claim 12 wherein the information presented on the display comprises a portion displaying at least a portion of the dynamic indication of equipment health.

21. The apparatus of claim 12 wherein the instrument further comprises a sound recorder and a microphone connected to the sound recorder, the sound recorder being controlled by the processor in cooperation with the user interface.

22. The apparatus of claim 12 further comprising:

a third sensor interface for a static sensor, the third sensor interface for a static sensor including electro-mechanics configured to receive static sensor data; and

a static sensor that is operatively connected to the third sensor interface for sending static data to the third sensor interface.

23. The apparatus of claim 12 wherein at least a portion of the application instructions is configured for analyzing waveforms to derive at least one dynamic indication of equipment health.

24. An apparatus for inspecting equipment, comprising:

a portable instrument comprising;

a first sensor interface for a focal plane array imaging sensor, the first sensor interface including electro-mechanics configured to receive imaging sensor data,

a second sensor interface for a dynamic sensor, the second sensor including electro-mechanics configured to receive dynamic sensor data,

a processor operatively connected to the first sensor interface and operatively connected to the second sensor interface,

a display that presents information,

a user interface that in cooperation with the processor controls what information is presented on the display, and

a wireless transmitter that is configured cooperatively with the processor to transmit at least a portion of the imaging sensor data and at least a portion of the dynamic sensor data;

a base station, the base station comprising;

a wireless receiver configured to receive at least a portion of imaging sensor data and at least a portion of dynamic sensor data transmitted by the transmitter in the portable instrument,

a central processor that is operatively connected to the receiver,

a station display that presents information, and

a station user interface that in cooperation with the central processor controls what information is presented on the station display.

25. The apparatus of claim 24 wherein the second sensor interface for a dynamic sensor comprises a sensor interface for a vibration sensor and the dynamic sensor comprises a vibration sensor.

26. The apparatus of claim 24 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array infrared imaging sensor and the imaging sensor comprises a focal plane array infrared imaging sensor.

27. The apparatus of claim 24 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array visible imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a vibration sensor and the 5 imaging sensor comprises a focal plane array visible imaging sensor and the dynamic sensor comprises a vibration sensor.

28. The apparatus of claim 24 wherein the first sensor interface for a focal plane array imaging sensor comprises a sensor interface for a focal plane array infrared imaging sensor and the second sensor interface for a dynamic sensor comprises a sensor interface for a sonic sensor and the imaging sensor comprises a focal plane array infrared imaging sensor and the dynamic sensor comprises a sonic sensor.

30. The apparatus of claim 24 wherein the base station is configured to be connected to the world-wide-web.

31. The apparatus of claim 24 wherein the portable instrument is configured to be connected to the world-wide-web.

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39. A method for inspecting equipment, the method comprising,

storing in an instrument (a) application instructions for receiving, storing and analyzing focal plane array imaging sensor data to derive at least one imagery indication of equipment health, and (b) application instructions for receiving, storing, and analyzing dynamic sensor data to derive at least one dynamic indication of equipment health, and (c) application instructions for correlating at least one imagery indication of equipment health with at least one dynamic indication of equipment health;

receiving and storing focal plane array imaging sensor data and dynamic sensor data in the instrument using at least a portion of the application instructions;

deriving at least one imagery indication of equipment health using at least a portion of the application instructions;

deriving at least one dynamic indication of equipment health using at least a portion of the application instructions; and

correlating at least one imagery indication of equipment health with at least one dynamic indication of equipment health.

40. The method of claim 39 wherein the step of storing in an instrument application instructions for receiving, storing and analyzing focal plane array imaging sensor data comprises storing in an instrument application instructions for receiving, storing and analyzing focal plane array infrared imaging sensor data, and the step of receiving and storing focal plane array imaging sensor data in the instrument comprises receiving and storing focal plane array infrared imaging sensor data in the instrument.

41. The method of claim 39 wherein the step of storing in an instrument application instructions for receiving, storing and analyzing dynamic sensor data comprises storing in an instrument application instructions for receiving, storing and analyzing dynamic sensor data using FFT analysis, and the step of deriving at least one dynamic indication of equipment health comprises deriving at least one dynamic indication of equipment health using FFT analysis.

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53. A method for inspecting equipment, the method comprising,

storing in an instrument application instructions for capturing and transmitting imaging sensor data from a focal plane array imaging sensor and application instructions for capturing and transmitting waveforms from a dynamic sensor;

storing in a base station application software for (a) receiving, storing and analyzing imaging sensor data to derive at least one imagery indication of equipment health, and (b) application software for receiving, storing, and analyzing waveforms to derive at least one dynamic indication of equipment health, and (c) application software for correlating at least one imagery indication of equipment health with at least one dynamic indication of equipment health;

capturing imaging sensor data with a focal plane array imaging sensor and transmitting at least a portion of the imaging sensor data from the instrument to the base station using at least a portion of the application software;

receiving and storing in the base station at least a portion of the imaging sensor data transmitted by the instrument using at least a portion of the application software;

capturing dynamic sensor data with a dynamic sensor and transmitting at least a portion of the dynamic sensor data from the instrument to a base station using at least a portion of the application software;

receiving and storing in the base station at least a portion of the dynamic sensor data transmitted by the instrument using at least a portion of the application software;

deriving at least one imagery indication of equipment health using at least a portion of the application software; and

deriving at least one dynamic indication of equipment health using at least a portion of the application software.

54. The method of claim 53 further comprising a step of correlating at least one imagery indication of equipment health with at least one dynamic indication of equipment health and producing at least one equipment health combined statistic.

55. The method of claim 53 wherein

the step of capturing imaging sensor data with a focal plane array imaging sensor comprises capturing imaging sensor data with a focal plane array infrared imaging sensor, and

the step of capturing dynamic sensor data with a dynamic sensor comprises capturing dynamic sensor data with a vibration sensor.

56. The method of claim 53 wherein

the step of capturing imaging sensor data with a focal plane array imaging sensor comprises capturing imaging sensor data with a focal plane array visible imaging sensor, and

the step capturing dynamic sensor data with a dynamic sensor comprises capturing dynamic sensor data with a vibration sensor.

57. The method of claim 53 wherein

the step of capturing imaging sensor data with a focal plane array imaging sensor comprises capturing imaging sensor data with a focal plane array infrared imaging sensor, and

the step capturing dynamic sensor data with a dynamic sensor comprises capturing dynamic sensor data with a sonic sensor.

58. A system for inspecting equipment, including a portable instrument comprising:

a focal play array imaging sensor selected from the group consisting of (a) an infrared focal plane array imaging sensor and (b) a visible focal plane array imaging sensor, the focal plane array imaging sensor being configured to generate imaging sensor data;

a dynamic sensor selected from the group consisting of (a) a vibration sensor and (b) a sonic sensor and (c) an ultrasonic sensor and (d) a flux sensor and (e) a current sensor, the dynamic sensor being configured to generate dynamic sensor data;

digital memory that stores an operating system and application instructions and a dataset;

a processor that runs the operating system and is operatively connected to the digital memory and operatively connected to the imaging sensor and is operatively connected to dynamic sensor, and where the processor is configured to use at least a portion of the application instructions for recording in the dataset at least a portion of the imaging sensor data and for recording in the dataset at least a portion of the dynamic sensor data, and where the processor is further configured to use at least a portion of the application instructions to operate on the imaging sensor data and the dynamic sensor data stored in the dataset and to derive at least one dynamic indication of equipment health;

a display that presents at least a portion of the imaging sensor data and presents at least a portion of the dynamic sensor data; and

a user interface that in cooperation with the processor controls what imaging sensor data and what dynamic sensor data is presented on the display.

59. The system of claim 58 wherein the processor is further configured to use at least a portion of the application instructions for establishing an association data element.

60. The system of claim 58 wherein the dynamic indication is derived at least in part using a Fast Fourier Transformation.

61. The system of claim 58 wherein a sensor selected from the group consisting of the imaging sensor and the dynamic sensor is configured to be operatively connected at least in part to the processor by a link selected from the group consisting of a wireless link and a cable link.

62. The system of claim 58 further including a base station, wherein the portable instrument is configured for transmitting at least a portion of the imaging sensor data and at least a portion of the dynamic sensor data to the base station, and the base station is configure for receiving and storing at least a portion of the imaging sensor data and at least a portion of the dynamic sensor data transmitted by the portable instrument.

63. A method for automating inspection of an equipment item using both imaging and dynamic signal analysis, the method comprising:

(a) providing a battery-operated inspection device having a processor, memory, a display having at least one window, data input, and a user interface;

(b) providing imaging data and dynamic signal data for the equipment item to the processor;

(c) using the processor to derive a dynamic indication of equipment health based upon a least a portion of the dynamic signal data;

(d) using the processor to establish an association data element; and

(e) providing a user interface selection to allow a user to view at least a portion of the imaging data and at least a portion of the dynamic indication of equipment health on at least one window on the display while the user performs the inspection.

64. The method of claim 63 wherein step (a) comprises providing a battery-operated device having imaging data input from a focal plane infrared camera and dynamic signal data input from an ultrasonic sensor and having a processor, memory, a display having at least one window, data input, and a user interface.

65. The method of claim 63 wherein a portion of the data provided to the processor in step (b) is provided to the processor from the memory.

66. The method of claim 63 wherein step (c) comprises using the processor to derive a dynamic indication if equipment health based upon a least a portion of the dynamic signal data using at least in part Fast Fourier Transformation.

67. The method of claim 63 further comprising a step of storing the association data element in the memory.

68. The method of claim 63 further comprising a step of reporting results.

69. The method of claim 63 further comprising a step of transferring to a base station at least a portion of the data provided to the processor in step (b).

70. The method of claim 63 wherein:

step (a) comprises providing a battery-operated inspection device having a processor, memory, a display having at least a first and a second window, and a user interface, and

step (e) comprises providing a user interface selection to allow a user to view at least a portion of the imaging data in the first window of the display and to view at least a portion of the dynamic indication of equipment health in the second window of the display.

71. The method of claim 63 wherein:

step (b) comprises providing live imaging data and dynamic signal data for the equipment item to the processor; and

step (e) comprises providing a user interface selection to allow a user to view at least a portion of the live imaging data and at least a portion of the dynamic indication of equipment health using at least one window on the display while the user performs the inspection.

72. The method of claim 63 wherein:

step (b) comprises providing imaging data and live dynamic signal data for the equipment item to the processor;

step (c) comprises using the processor to derive a current dynamic indication of equipment health based upon at least a portion of the live dynamic signal data; and

step (e) comprises providing a user interface selection to allow a user to view at least a portion of the imaging data and at least a portion of the current dynamic indication of equipment health using at least one window on the display while the user performs the inspection.

73. The method of claim 63 further comprising:

using the processor and the imaging data and the dynamic sensor data to produce an equipment health combined statistic; and

providing a user interface selection allowing a user to view at least a portion of the equipment health combined statistic using at least one window on the display.

74. The method of claim 63 wherein step (e) comprises providing a user interface selection to allow a user to simultaneously view at least a portion of the imaging data and at least a portion of the dynamic indication of equipment health on at least one window on the display while the user performs the inspection.