METHOD OF MONITORING EQUIPMENT/S OVER AN INSTALLED BASE FOR IMPROVING THE EQUIPMENT DESIGN AND PERFORMANCE

• US 20120053979A1
• Filed: 04/26/2010
• Published: 03/01/2012
• Est. Priority Date: 05/04/2009
• Status: Abandoned Application

• Current Assignee: Ecoaxis Systems Pvt Ltd.
• Original Assignee: Ecoaxis Systems Pvt Ltd.
• Inventors: Nalawade, Abhay
• Application Number:
  US13/318,578
• Publication Number:
  US 20120053979A1
• Time in Patent Office: Days
• US Class Current: 705/7.23
• CPC Class Codes: G05B 19/4183 characterised by data acquisition, e.g. workpiece identification
• CPC Class Codes: G05B 2219/31217 Merge, synchronize process data and network data for trend analysis
• CPC Class Codes: G05B 2219/31282 Data acquisition, BDE MDE
• CPC Class Codes: G05B 2219/31316 Output test result report after testing, inspection
• CPC Class Codes: G05B 2219/31336 Store machines performance; use it to control future machining
• CPC Class Codes: G05B 23/0232 based on qualitative trend analysis, e.g. system evolution
• CPC Class Codes: G06Q 10/06313 Resource planning in a project environment
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

Method for improving/optimizing equipment design for an installed base of engineering equipment and for managing equipment operation is disclosed. In one instance, the method includes continuously acquiring, utilizing acquisition systems, (measurements) data for equipment operating conditions, equipment environment conditions, energy consumed by the equipment, utilities consumed b\ the equipment, wastages resulting from the process, input data and output data of each one of a number of pieces of equipment, each one piece of equipment—belonging to an installed base of the same class equipment pieces, and analyzing, utilizing one or more processors, the acquired data in order to obtain patterns and relations for the installed base; the patterns and relations comprising factors that affect performance and efficiency, the patterns and relations being used for equipment design improvement/optimization and installed base management. In one instance, the method also includes recording (storing) the analysis results and providing the analysis results in multiple formats to desired stakeholders, such as original equipment manufacturers (OEMs) the format being customized to the intended recipient/stake-holder.

Claims

1-19. -19. (canceled)

20. A method for improving design of equipments from equipment installed base, the method comprising the steps of:

i. acquiring a plurality of pre-defined parameters from equipment installed base located at multiple geographic locations, each one piece of equipment belonging to the same class equipment of equipment installed base;

ii. communicating by way of a communication network of remote system to acquire data, the remote system comprising a device having at least one data server, application server and one or more processors wherein the pre-defined parameters is recorded;

iii. processing and analysing the acquired data by the device, the analysis results being stored in an internal or external storage device of the remote system; and

iv. providing the analysis results to at least one of desired stakeholders;

the patterns and relations of the analysis results being used to improve the design of the equipments.

21. The method of claim 20, further for improving operation, reliability, maintenance and service for equipment installed base.

22. The method of claim 20, wherein the plurality of pre-defined parameters is acquired in a desired manner on a continuous basis.

23. The method of claim 20, wherein the plurality of pre-defined parameters is acquired in intervals which can be configured by the stakeholders.

24. The method of claim 20, wherein the plurality of pre-defined parameters is acquired on occurrence of a defined event or on request obtained from the stakeholder.

25. The method of claim 24, wherein the defined event comprises occurrence of any of events such as equipment failure, pre-defined equipment condition, pre-defined deviation of any of parameter value from the configured set-points of the installed equipment, and/or the configured instance specific set-points of the installed equipment.

26. The method of claim 20, wherein the step of acquiring the data utilizes at least one of:

i. configured set points of the installed equipment that are common to the entire family of the same class equipment;

ii. configured set points of the installed equipment, those are specific to particular instances of installed equipment;

iii. directly from the equipment control system;

iv. directly from sensors, transducers, meters and instruments;

v. derived parameters, the derived parameters comprising parameters obtained as a result of manipulation of at least one of other acquired parameters and/or the equipment set-points of the installed equipment;

vi. manually inputting parameters through an interface provided for said purpose, the said interface comprising web-enabled devices.

27. The method of claim 20, wherein the plurality of pre-defined parameters acquired comprise that are relevant for measurement of performance and efficiency of each one of a plurality of equipment installed base, each one piece of equipment belonging to the same class equipment from said plurality of equipment installed base.

28. The method of claim 20, wherein the plurality of pre-defined parameters acquired comprise any of equipment operating conditions, equipment environment conditions, input data and output data, energy consumed by the equipment, utilities consumed by the equipment, wastages resulting from the process.

29. The method of claim 20, wherein the patterns and relations of analysis results comprise factors affecting performance, efficiency and reliability.

30. The method of claim 20, wherein the step of providing includes providing the analysis results in at least one of the plurality of formats such as graphical user interface, charts, tabular, printed.

31. The method of claim 20, wherein the step of providing includes providing the analysis results of the remote system on request/demand obtained from user.

32. The method of claim 20, wherein the step of providing includes providing the analysis results of the remote system on occurrence of a defined event.

33. The method of claim 32, wherein the defined event comprises occurrence of any of events such as equipment failure, pre-defined equipment condition, pre-defined deviation of any of parameter value from the configured set-points, and/or the configured instance specific set-points of installed equipment.

34. The method of claim 20, wherein the step of providing includes providing the analysis results of the remote system on continuous/ongoing basis.

35. The method of claim 20, wherein the step of providing the analysis results includes transmitting in a selectable format, the format being customized according to the intended recipient stakeholder, the analysis results to the desired stakeholder by wireless means such as SMS, or an open network, wherein the open network is the interne.

36. The method of claim 20, wherein the step of analyzing further comprises the steps of:

i. filtering the acquired data according to configured logic, to substantially discard irrelevant data;

ii. storing the said data obtained by filtering in storage means provided for said purpose, said storage means comprising any of data servers, application server.

iii. evaluating, from the filtered data of each of the instantiation of the installed equipment substantially instantaneous values of individual parameters;

iv. evaluating relationship/ratios between the parameter values for each of the instantiation of the equipment;

v. calculating and evaluating key performance indicators those relevant to performance, efficiency and reliability for each instantiation of the equipment;

vi. evaluating the relationship/ratios between the key performance indicators, for each of the instantiation of the equipment;

vii. determining, from the results obtained from the aforesaid steps of analysis, condition of failure or breakdown;

viii. evaluating based on the data obtained, for each of the instantiation of the installed equipment and the collated data from the equipment installed base, each one piece of equipment from said equipment installed base belonging to same class equipment, the performance, efficiency and reliability of each of the instantiation of the equipment and the equipment class;

ix. repeating the above steps over a period of time and collating the results data;

x. recording the results data and the parameter data, relationship/ratios data, key performance indicator data in at least one data storage means such as server;

xi. reporting according to the configured rules the said results data and optionally the other data to the at least one desired stakeholder.

37. The method of claim 36, wherein the step of evaluating the filtered data further comprises evaluating by comparison each of the parameter against certain pre-configured values and/or range of values, whereby deviations, if any, from the pre-configured limits/ranges is determined, further recording each of the occurrence of such deviation/s along with the acquired parametric data at the given instance of each such deviation and optionally determining tendency in the changes in the substantially instantaneous values, relationship/ratios between any of the acquired parameters, observed deviations in such values.

38. The method of claim 21, wherein the plurality of pre-defined parameters is acquired in a desired manner on a continuous basis.

39. The method of claim 21, wherein the plurality of pre-defined parameters is acquired in intervals which can be configured by the stakeholders.

40. The method of claim 21, wherein the plurality of pre-defined parameters is acquired on occurrence of a defined event or on request obtained from the stakeholder.

41. The method of claim 21, wherein the plurality of pre-defined parameters is acquired on occurrence of a defined event or on request obtained from the stakeholder.

42. The method of claim 41, wherein the defined event comprises occurrence of any of events such as equipment failure, pre-defined equipment condition, pre-defined deviation of any of parameter value from the configured set-points of the installed equipment, and/or the configured instance specific set-points of the installed equipment.

43. The method of claim 21, wherein the step of acquiring the data utilizes at least one of:

i. configured set points of the installed equipment that are common to the entire family of the same class equipment;

ii. configured set points of the installed equipment, those are specific to particular instances of installed equipment;

iii. directly from the equipment control system;

iv. directly from sensors, transducers, meters and instruments;

v. derived parameters, the derived parameters comprising parameters obtained as a result of manipulation of at least one of other acquired parameters and/or the equipment set-points of the installed equipment;

vi. manually inputting parameters through an interface provided for said purpose, the said interface comprising web-enabled devices.

44. The method of claim 21, wherein the plurality of pre-defined parameters acquired comprise that are relevant for measurement of performance and efficiency of each one of a plurality of equipment installed base, each one piece of equipment belonging to the same class equipment from said plurality of equipment installed base.

45. The method of claim 21, wherein the plurality of pre-defined parameters acquired comprise any of equipment operating conditions, equipment environment conditions, input data and output data, energy consumed by the equipment, utilities consumed by the equipment, wastages resulting from the process.

46. The method of claim 21, wherein the patterns and relations of analysis results comprise factors affecting performance, efficiency and reliability.

47. The method of claim 21, wherein the step of providing includes providing the analysis results in at least one of the plurality of formats such as graphical user interface, charts, tabular, printed.

48. The method of claim 21, wherein the step of providing includes providing the analysis results of the remote system on request/demand obtained from user.

49. The method of claim 21, wherein the step of providing includes providing the analysis results of the remote system on occurrence of a defined event.

50. The method of claim 49, wherein the defined event comprises occurrence of any of events such as equipment failure, pre-defined equipment condition, pre-defined deviation of any of parameter value from the configured set-points, and/or the configured instance specific set-points of installed equipment.

51. The method of claim 21, wherein the step of providing includes providing the analysis results of the remote system on continuous/ongoing basis.

52. The method of claim 21, wherein the step of providing the analysis results includes transmitting in a selectable format, the format being customized according to the intended recipient stakeholder, the analysis results to the desired stakeholder by wireless means such as SMS, or an open network, wherein the open network is the internet.

53. The method of claim 21, wherein the step of analyzing further comprises the steps of:

i. filtering the acquired data according to configured logic, to substantially discard irrelevant data;

ii. storing the said data obtained by filtering in storage means provided for said purpose, said storage means comprising any of data servers, application server.

iii. evaluating, from the filtered data of each of the instantiation of the installed equipment substantially instantaneous values of individual parameters;

iv. evaluating relationship/ratios between the parameter values for each of the instantiation of the equipment;

v. calculating and evaluating key performance indicators those relevant to performance, efficiency and reliability for each instantiation of the equipment;

vi. evaluating the relationship/ratios between the key performance indicators, for each of the instantiation of the equipment;

vii. determining, from the results obtained from the aforesaid steps of analysis, condition of failure or breakdown;

viii. evaluating based on the data obtained, for each of the instantiation of the installed equipment and the collated data from the equipment installed base, each one piece of equipment from said equipment installed base belonging to same class equipment, the performance, efficiency and reliability of each of the instantiation of the equipment and the equipment class;

ix. repeating the above steps over a period of time and collating the results data;

x. recording the results data and the parameter data, relationship/ratios data, key performance indicator data in at least one data storage means such as server;

xi. reporting according to the configured rules the said results data and optionally the other data to the at least one desired stakeholder.

54. The method of claim 53, wherein the step of evaluating the filtered data further comprises evaluating by comparison each of the parameter against certain pre-configured values and/or range of values, whereby deviations, if any, from the pre-configured limits/ranges is determined, further recording each of the occurrence of such deviation/s along with the acquired parametric data at the given instance of each such deviation and optionally determining tendency in the changes in the substantially instantaneous values, relationship/ratios between any of the acquired parameters, observed deviations in such values.