METHOD FOR GENERATING A MACHINE HEARTBEAT

• US 20120310865A1
• Filed: 06/01/2012
• Published: 12/06/2012
• Est. Priority Date: 06/03/2011
• Status: Active Grant

• Current Assignee: Beet, LLC
• Original Assignee: Beet, LLC
• Inventors: Wang, David J.
• Granted Patent: US 8,880,442 B2
• Time in Patent Office: Days
• US Class Current: 706/12
• CPC Class Codes: G05B 23/0232 based on qualitative trend analysis, e.g. system evolution
• CPC Class Codes: G06F 11/3006 where the computing system is distributed, e.g. networked systems, clusters, multiprocessor systems multiprogramming arrangements G06F9/46; allocation of resources G06F9/50
• CPC Class Codes: G06F 11/3082 the data filtering being achieved by aggregating or compressing the monitored data
• CPC Class Codes: G06F 9/46 Multiprogramming arrangements

Abstract

A method and system for generating a heartbeat of a process including at least one machine configured to perform a process cycle consisting of a plurality of timed events performed in a process sequence under an identified condition includes determining the duration of each of the timed events during the process cycle performed under the identified condition, ordering the durations of the plurality of timed events in the process sequence, and generating a heartbeat defined by the ordered durations of a process cycle. The identified condition may be one of a design intent, baseline, learnt, known, current or prior condition. The variance of the heartbeat between a first and at least a second identified condition may be analyzed to monitor and/or control the process or machine. The system may display the process heartbeat information and may generate a message in response to the heartbeat and/or variance thereof.

Claims

1. A method for generating a heartbeat of a process, wherein the process includes at least one machine performing a process cycle, and wherein the process cycle includes a plurality of timed events performed in a process sequence, the method comprising:

identifying a baseline duration of each of the plurality of timed events of a baseline process cycle;

ordering the baseline durations of the plurality of timed events in the process sequence; and

generating, via a server, a baseline heartbeat defined by the ordered baseline durations of the baseline process cycle.

2. The method of claim 1, wherein the baseline duration of each of the plurality of events is the design intent duration of the respective event.

3. The method of claim 1, further comprising:

performing a learnt process cycle under a known condition;

measuring a learnt duration of each of the plurality of timed events, wherein the learnt duration of each of the timed events corresponds to the duration of the respective timed event while performing the process cycle under the known condition;

ordering the learnt durations of the plurality of timed events in the process sequence; and

generating a learnt heartbeat defined by the ordered learnt durations.

4. The method of claim 3, further comprising:

determining a learnt event variance between the learnt duration and the baseline duration for each of the plurality of timed events.

5. The method of claim 4, further comprising:

determining a learnt cumulative variance between the learnt heartbeat and the baseline heartbeat;

wherein the learnt cumulative variance is defined by the sum of the learnt event variances of the plurality of timed events.

6. The method of claim 3, wherein the known condition includes at least one known process parameter.

7. The method of claim 6, further comprising:

providing a process specification for the process;

wherein the at least one known process parameter complies with the process specification.

8. The method of claim 1, further comprising:

performing a current process cycle under a current condition;

measuring a current duration of each of the plurality of timed events, wherein the current duration corresponds to the duration of the respective timed event while performing the process cycle under the current condition;

ordering the current durations of the plurality of timed events in the process sequence; and

generating a current heartbeat defined by the ordered current durations.

9. The method of claim 8, further comprising:

determining a current event variance between the current duration and the learnt duration for each of the plurality of timed events.

10. The method of claim 9, further comprising:

determining a current cumulative variance between the current heartbeat and the learnt heartbeat;

wherein the current cumulative variance is defined by the sum of the current event variances of the plurality of timed events.

11. The method of claim 10, further comprising:

generating a message in response to one of the current event variance and the first current cumulative variance.

12. The method of claim 11, wherein the message is at least one of:

a maintenance indicator;

a cycle time indicator; and

a shutdown signal.

13. The method of claim 8, further comprising:

generating a plurality of current heartbeats, wherein each respective heartbeat of the plurality of current heartbeats is defined by a respective current process cycle performed under a respective current condition at a respective time;

associating each respective heartbeat of the plurality of current heartbeats with the respective time; and

comparing each respective heartbeat of the plurality of current heartbeats with a plurality of prior heartbeats;

wherein the plurality of prior heartbeats includes two or more of the baseline heartbeat, the learnt heartbeat, and current heartbeats generated prior to the respective time associated with the respective heartbeat.

14. The method of claim 13, wherein comparing each respective heartbeat of the plurality of current heartbeats with a plurality of prior heartbeats includes at least one of:

determining a current event variance between the current duration of the respective heartbeat and the learnt duration for each of the plurality of timed events.

determining a current cumulative variance between the respective heartbeat and the learnt heartbeat;

wherein the current cumulative variance is defined by the sum of the current event variances of the plurality of timed events; and

identifying a process trend defined by the respective heartbeat and the plurality of prior heartbeats.

15. The method of claim 14, further comprising:

generating a message in response to one of the current event variance of the respective heartbeat, the current cumulative variance of the respective heartbeat, and the process trend.

16. A system for generating a heartbeat of a process, wherein the process includes at least one machine performing a process cycle, wherein the process cycle consists of a plurality of timed events performed in a process sequence, the system comprising:

a server in communication with the at least one machine and configured to generate a heartbeat for the at least one machine, wherein the server generates the heartbeat by;

receiving measurements of the duration of each of the plurality of timed events, wherein the duration of each of the timed events corresponds to the duration of the timed event while the at least one machine is performing the process cycle under an identified condition;

ordering the durations of the plurality of timed events in the process sequence; and

generating a heartbeat for the identified condition defined by the ordered durations.

17. The system of claim 16, wherein the identified condition is one of:

a design intent condition defining a baseline heartbeat;

a known condition defining a learnt heartbeat; and

a current condition defining a current heartbeat.

18. The system of claim 17, wherein the server is configured to:

determine a learnt event variance between the learnt duration and the baseline duration for each of the plurality of timed events;

determine a current event variance between the current duration and the learnt duration for each of the plurality of timed events;

determine a learnt cumulative variance between the learnt heartbeat and the baseline heartbeat, wherein the learnt cumulative variance is defined by the sum of the learnt event variances of the plurality of timed events; and

determine a current cumulative variance between the current heartbeat and the learnt heartbeat, wherein the current cumulative variance is defined by the sum of the current event variances of the plurality of timed events.

19. The system of claim 18, wherein the server is configured to generate a message based on one of the current event variance and the current cumulative variance.

20. The system of claim 19, wherein the message is one of:

a maintenance indicator; and

a cycle time indicator.

21. The system of claim 19, wherein the message is a shutdown signal providing to the at least one machine.

22. The system of claim 19, further comprising:

an interface device in communication with the server;

wherein the interface device is configured to receive the message from the server and to output the message to one of a user interface and the at least one machine.

23. The system of claim 22, wherein the user interface includes one of a display and an alarm.

24. The system of claim 22, wherein the interface device is a programmable controller in communication with the at least one machine and configured to measure the duration of each of the plurality of timed events.

25. The system of claim 19, further comprising:

a database in communication with the server and configured to store a plurality of prior heartbeats generated by the server;

wherein the server if configured to compare a respective current heartbeat with the plurality of prior heartbeats; and

wherein the plurality of prior heartbeats includes at least two of;

the baseline heartbeat;

the learnt heartbeat; and

a prior heartbeat;

wherein the prior heartbeat is defined by the current heartbeat generated prior to the time associated with the respective current heartbeat.

26. The system of claim 25, wherein the server is configured to generate a message based on one of:

the current event variance of the respective current heartbeat;

the current cumulative variance of the respective current heartbeat;

and a process trend including the respective current heartbeat.