SYSTEM AND METHOD FOR MONITORING AND ANALYZING INDUSTRIAL OPERATIONS

• US 20170235292A1
• Filed: 02/11/2016
• Published: 08/17/2017
• Est. Priority Date: 02/11/2016
• Status: Active Grant

• Current Assignee: Glen C. Wernersbach, Philip Wernersbach
• Original Assignee: Glen C. Wernersbach, Philip Wernersbach
• Inventors: Wernersbach, Philip, Wernersbach, Glen C.
• Granted Patent: US 10,310,474 B2
• Time in Patent Office: Days
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 2219/14006 Safety, monitoring in general
• CPC Class Codes: G05B 2219/31208 Server node to watch, store message, variable, data between lon, network
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An industrial system and method for monitoring and analyzing industrial operations such that data is obtained from one or more sensors of one or more industrial components and transmitted to a master controller as a data stream through a communication network, the transmitted data is captured, copied, and stored for analysis without interfering with the data stream.

Claims

1. An industrial system for monitoring and analyzing industrial operations comprising:

at least one industrial component having at least one sensor and operates to obtain data on said at least one industrial component;

a communication network for transmitting said data to a master controller;

a performer for copying said data being transmitted by said communication network without interfering with said data being transmitted to said master controller; and

a databank for storing said data copied by said performer in a query-able database.

2. The industrial system of claim 1 further comprising an analyzer that operates to select all or portions of said data copied by said performer and stored in said query-able database and makes a comparison of said data to reference data and determines using said comparison if said at least one industrial component is properly performing within operating specifications.

3. The industrial system of claim 1 further comprising an analyzer that operates to select all or portions of said data copied by said performer and stored in said query-able database and makes a comparison of said data to reference data and using said comparison to determine if specific elements comprising said at least one industrial component is operating within operating specifications.

4. The industrial system of claim 1 further comprising an analyzer that operates to analyze said data copied by said performer and stored in said query-able database prior to said at least one industrial component having an error or malfunction.

5. The industrial system of claim 1 further comprising an analyzer that operates to analyze said data copied by said performer and stored in said query-able database prior to said at least one industrial component having an error or malfunction and further operates to determines the possibility that an error or malfunction may occur and if the possibility is more than a predetermined level, said analyzer transmits a warning to a human-machine interface.

6. The industrial system of claim 1 further comprising an analyzer that operates to make a comparison of historical data for one or more industrial components that have sustained an error or malfunction with data copied by said performer for said at least one industrial component prior to having an error or malfunction and operates to make recommendations with regard to said at least one industrial component based on said comparison.

7. The Industrial system of claim 1 wherein said data being transmitted through said communication network is in the form of data packages, whereby metadata is appended to each data packet and whereby said data packets are compressed and bunched together into optimized sized bytes and stored in said query-able database.

8. An industrial system for monitoring and analyzing industrial operations comprising:

at least one industrial component having at least one sensor that operates to obtain data from at least one sensor;

at least one component control system that operates to receive said data and to transmit said data in the form of a data stream through a communication network to a master controller;

a performer in communication with said communication network and operates to copy said data from said data stream without impeding the data stream;

wherein said performer further operates to convert said data copied by said performer into a query-able format and stores said converted data in a query-able database.

9. The industrial system of claim 8 further comprising an analyzer that operates to select all or portions of said data copied by said performer and stored in said query-able database and makes a comparison of said data to reference data and determines using said comparison if said at least one industrial component is performing within operation specifications.

10. The industrial system of claim 8 further comprising an analyzer that operates to select al or portions of said data copied by said performer and stored in said query-able database and makes a comparison of said data to reference data and using said comparison to determine if specific elements comprising said at least one industrial component is operating within operating specifications.

11. The industrial system of claim 8 further comprising an analyzer that operates to analyze said data copied by said performer and stored in said query-able database prior to said at least one industrial component having an error or malfunction.

12. The industrial system of claim 8 further comprising an analyzer that operates to analyze said data copied by said performer and stored in said query-able database prior to said at least one industrial component having an error or malfunction and further operates to determines the possibility that an error or malfunction may occur and if the possibility is more than a predetermined level, said analyzer transmits a warning to a human-machine interface.

13. The industrial system of claim 8 further comprising an analyzer that operates to make a comparison of historical data for one or more industrial components that have sustained an error or malfunction with data copied by said performer for said at least one industrial component prior to having an error or malfunction and operates to make recommendations with regard to said at least one industrial component based on said comparison.

14. The industrial system of claim 8 wherein said data being transmitted through said communication network is in the form of data packages, whereby metadata is appended to each data packet and whereby said data packets are compressed and bunched together into optimized sized bytes and stored in said query-able database.

15. The industrial system of claim 8 wherein said data being transmitted through said communication network is in the form of data packages, whereby metadata is appended to each data packet and whereby said data packets are compressed and bunched together into optimized sized bytes and stored in said query-able database.

16. An industrial system for monitoring and analyzing industrial operations comprising:

one or more industrial components each having one or more sensors that operate to obtain data related to the operation of said one or more industrial components whereby said data is transferred to a master controller;

an analyzer that receives said data and operates to select all or portions of said data and makes a comparison of said data to reference data and determines using said comparison if said one or more industrial components are properly performing within operating specifications and/or if said one or more industrial components are predicted to fail within a predefined time segment;

wherein said analyzer further operates to transmit a warning if said one or more industrial components are not performing within operating specifications and/or if said one or more industrial components are predicted to fail within a predefined time segment.

17. The industrial system of claim 16 wherein said analyzer further operates to make a recommendation with regard to said one or more industrial components based on said comparison.