Apparatus and Method for Sensing Inappropriate Operational Behavior by Way of an Array of Acoustical Sensors

• US 20080147356A1
• Filed: 12/14/2007
• Published: 06/19/2008
• Est. Priority Date: 12/14/2006
• Status: Abandoned Application

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Leard, Frank L., Manjunath, Hassan R.
• Application Number:
  US11/956,908
• Publication Number:
  US 20080147356A1
• Time in Patent Office: Days
• US Class Current: 702/183
• CPC Class Codes: G01H 3/04 Frequency
• CPC Class Codes: G01H 3/10 Amplitude; Power

Abstract

An apparatus and method for detecting behavior of one or more pieces of equipment of a system within a facility are disclosed. In at least one embodiment, the apparatus includes an array of acoustic sensors respectively positioned at a variety of respective locations within the facility, where each of the respective acoustic sensors detects respective sounds arriving at the respective sensor from the system, including the piece of equipment. The apparatus further includes a processing device coupled to the acoustic sensors of the array, where the processing device monitors sonic information provided by the acoustic sensors in response to the sounds detected by the acoustic sensors, and detects inappropriate behavior of the piece of equipment based upon the monitored sonic information.

Claims

1. An apparatus for detecting inappropriate behavior of a piece of equipment of a system within a facility, the apparatus comprising:

an array of acoustic sensors respectively positioned at a variety of respective locations within the facility, wherein each of the respective acoustic sensors detects respective sounds arriving at the respective sensor from the system, including the piece of equipment; and

a processing device coupled to the acoustic sensors of the array, wherein the processing device monitors sonic information provided by the acoustic sensors in response to the sounds detected by the acoustic sensors, and detects the inappropriate behavior of the piece of equipment based upon the monitored sonic information.

2. The apparatus of claim 1, wherein the array of acoustic sensors includes at least first and second acoustic sensors that are positioned at first and second locations that differ from one another.

3. The apparatus of claim 2, wherein the sonic information provided to the processing device includes first sonic information provided by the first acoustic sensor in response to first sounds detected by the first acoustic sensor, and also includes second sonic information provided by the second acoustic sensor in response to second sounds detected by the second acoustic sensor.

4. The apparatus of claim 3, wherein the processing device performs a triangulation operation by which the processing device calculates at least one of an identity and a position of the piece of equipment based upon the first and second sonic information.

5. The apparatus of claim 1, wherein the respective sounds received by the respective acoustic sensors are produced by the piece of equipment and at least one additional piece of equipment of the system.

6. The apparatus of claim 5, wherein the respective sounds received by the respective acoustic sensors each include a respective set of first and second sound components, and wherein the amplitude of at least one of the sound components of the set received by a first of the respective acoustic sensors differs from the amplitude of the corresponding at least one of the sound components of the set received by a second of the respective acoustic sensors.

7. The apparatus of claim 5, wherein the piece of equipment is selected from the group consisting of a motor, a generator, another electromechanical device, and another mechanical device.

8. The apparatus of claim 1, wherein the processing device is a computer that includes or is in communication with a memory device, the memory device storing information regarding at least one characteristic sound component of the piece of equipment.

9. The apparatus of claim 8, wherein the processing device identifies a portion of the monitored sonic information as being representative of specific sounds produced by the piece of equipment by comparing at least some of the monitored sonic information with the at least one characteristic sound component of the piece of equipment.

10. The apparatus of claim 8, wherein the processing device determines that the inappropriate behavior has occurred by comparing at least some of the monitored sonic information with the at least one characteristic sound component of the piece of equipment.

11. The apparatus of claim 8, wherein the at least one characteristic sound component includes at least one of a first sonic component produced by the piece of equipment when the piece of equipment is operating normally, a second sonic component produced by the piece of equipment when the piece of equipment is operating abnormally, a third sonic component produced by the piece of equipment when an additional piece of equipment is operating normally, and a fourth sonic component produced by the additional piece of equipment when the additional piece of equipment is operating abnormally.

12. The apparatus of claim 1, wherein the array of acoustical sensors includes a plurality of acoustical sensors arranged around a perimeter of the system and connected with one another and the processing device by way of at least one wireless or wired connection link.

13. The apparatus of claim 1, wherein the processing device provides at least one of a signal to an operator indicative of the inappropriate behavior and a command to a controlled device upon determining that the inappropriate behavior has occurred.

14. An apparatus for monitoring changes in a piece of equipment comprising:

at least one acoustical sensor located within proximity of the piece of equipment, for receiving at least one sound input therefrom, and

a processing device in communication with the at least one acoustical sensor such that the at least one sound input can be monitored as a sound signature by the processing device,

wherein the processing device communicates with a catalog of sound signatures and performs a comparison of the monitored sound signature with at least one of the catalogued sound signatures, the catalog including sound signatures from at least one of a properly functioning piece of equipment and an improperly functioning piece of equipment, and

wherein the processing device further performs an additional action upon determining that a change has occurred in the piece of equipment based upon the comparison.

15. The apparatus of claim 14, wherein the comparison involves a determination of whether there is an exact match or a substantial match between the monitored sound signature and the at least one catalogued sound signature.

16. The apparatus of claim 14 further including, a recording device in communication with the processing device for creating catalog entries from a monitored sound signature.

17. The apparatus of claim 14, wherein the array is situated at least partially around the piece of equipment and additional pieces of equipment, wherein the processing device receives respective sound inputs from each of the acoustical sensors in the array, and wherein the processing device performs at least one triangulation calculation to distinguish a particular sound signature of the piece of equipment apart from other sound signatures of the additional pieces of equipment.

18. The apparatus of claim 14, further comprising means for allowing a user to remotely access the processing device.

19. A method for detecting inappropriate behavior of a piece of equipment of a system within a facility, the method comprising:

positioning an array of acoustic sensors at a variety of respective locations within the facility;

detecting sound information produced by the system including the piece of equipment with the acoustic sensors;

processing at least some of the detected sound information at a processing device, wherein the processing includes comparing at least a portion of the detected sound information with stored sound signature information and, based upon the comparing, determining if the inappropriate behavior of the piece of equipment has occurred; and

taking a further action upon the determining, the further action including at least one of sending a signal to a user indicative of the inappropriate behavior, sending a message to a logging device regarding the inappropriate behavior, causing a shutdown of at least a part of the system, and generating an additional command.

20. The method of claim 19, wherein the processing includes recording and storing of the sound signature information.

21. The method of claim 19, wherein the processing includes monitoring a change in the detected sound information that occurs over time.

22. The method of claim 19, wherein the processing further includes triangulating the sound signature detected to identify specific sound signatures for different pieces of equipment of the system.

23. The method of claim 19, wherein the processing additionally includes identifying a particular sound signature from among the detected sound information.

24. The method of claim 19, wherein the processing further includes performing a calculation based upon the monitored sonic information, and determining an identity of the piece of equipment.

25. The method of claim 19, wherein the inappropriate behavior is behavior indicating that the piece of equipment is potentially about to experience a failure.