Method of data compression and apparatus for its use in monitoring machinery

• US 5,602,749 A
• Filed: 01/12/1995
• Issued: 02/11/1997
• Est. Priority Date: 01/12/1995
• Status: Expired due to Fees

• Current Assignee: MTC Ltd
• Original Assignee: MTC Ltd
• Inventors: Vosburgh, Frederick
• Primary Examiner(s): Voeltz, Emanuel T.
• Assistant Examiner(s): MILLER, CRAIG S
• Application Number:
  US08/372,046
• Time in Patent Office: 761 Days
• Field of Search: 364/424.01, 364/424.06, 364/474.16, 364/474.17, 364/506, 364/508, 364/550, 364/551.01, 73/570, 73/577, 73/658, 73/660, 340/679, 340/683, 395/600, 341/123
• US Class Current: 700/174
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
• CPC Class Codes: G05B 23/0235 based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
• CPC Class Codes: G07C 3/00 Registering or indicating the condition or the working of machines or other apparatus, other than vehicles
• CPC Class Codes: H03M 7/3059 Digital compression and data reduction techniques where the original information is represented by a subset or similar information, e.g. lossy compression
• CPC Class Codes: Y10S 707/99945 Object-oriented database structure processing
• CPC Class Codes: Y10S 707/99948 Application of database or data structure, e.g. distributed, multimedia, or image

Abstract

The present invention relates to a method and apparatus for monitoring machinery in which data is collected and stored based on application specific retention rules. Based on an alarm value, data records are adjusted by reducing the spectral resolution, coefficient precision and time intervals between records. An alarm is activated when the data value is greater than a predetermined alarm threshold value. Memory management can compare the memory availability to projected requirements. If the projected memory requirements exceeds memory availability, the data records can be interactively decimated. When decimation cannot make available sufficient memory for projected requirements within the retention rules, an alarm is issued. Collected data can be transferred with a removable nonvolatile memory or infrared communications with a computer device.

Claims

1. A method for monitoring machinery comprising the steps of:

a. collecting sensor signals from said machinery, said sensor signals each having a time stamp;

b. converting said sensor signals into digital time domain data;

c. transforming said digital time domain data into frequency domain data, which both together comprise processed data;

d. comparing said processed data against alarm threshold values to determine an alarm condition;

e. forming data records of said processed data and said time stamps;

f. comparing said processed data to data retention rules which increase the density of data storable as said sensor signals approach said alarm threshold;

g. storing said data records in memory storage means; and

h. selectively removing certain of said stored data records in order to permit greater spacing between data records of lower level signals than that of higher level signals.

2. The method of claim 1 further comprising the step of communicating said stored data record to a remote computer.

3. The method of claim 2 wherein said processed data is compared to said alarm threshold for storage in said memory means according to said retention rule.

4. The method of claim 3 wherein said processed data comprise a spectrum.

5. The method of claim 4 wherein a plurality of said spectrum formed in an hour time period are averaged together to provide an hourly averaged spectrum.

6. The method of claim 5 further comprising the step of:

computing an average daily spectrum from said stored hourly average spectra.

7. The method of claim 6 further comprising the steps of:

storing said average daily spectrum in said storage means; and

deleting said stored hourly averaged spectra from said storage means.

8. The method of claim 7 further comprising the step of:

comparing said time domain data to a trigger threshold before said step of transforming said digital time domain data and (i) if said time domain data is less than said trigger threshold repeating said step (a) of collecting sensor signals, or (ii) if said time domain vibration data is greater than said trigger threshold performing said transforming step.

9. The method of claim 8 further comprising the steps of:

communicating to a remote computer; and

transferring said stored daily average spectrum to said remote computer.

10. The method of claim 9 further comprising the step of:

issuing an alarm when the value of said processed data is greater than said alarm threshold value.

11. The method of claim 10 further comprising the steps of:

comparing the memory availability, MA_j, of said storage means against a projected memory requirement PR_j and if said memory availability MA_j is less than said projected memory PR_j deleting certain said stored data records.

12. The method of claim 11 wherein said communicating step is performed with an infrared connection.

13. The method of claim 12 wherein said storage means has a non-volatile removable portion and said transferring step is performed by removing said nonvolatile removable portion from said storage means.

14. The method of claim 1 wherein said sensor signals represent vibration data.

15. A method for managing memory in a monitoring system comprising the steps of:

determining a series of data records containing said processed data;

determining a daily average of said data records;

storing said daily average of said data records in accordance with a predetermined time interval determined by a set of retention rules,

wherein said retention rules which increase the density of data storable as said data records approach an alarm value are based on a comparison of the value of said series of data records to said alarm value.

16. The method of claim 15 wherein said retention rules direct reduction of the resolution and precision of said spectrum in said stored daily average when said value of said series of data records is low relative to said alarm value.

17. The method of claim 16 wherein said time interval between said stored records has a maximum value.

18. The method of claim 17 further comprising the step of:

issuing an alarm when said processed data to said alarm threshold is greater than a predetermined value.

19. An apparatus for monitoring machinery comprising:

sensor means attached to said machinery for providing sensor signals;

means for converting said sensor signals into digital time domain data;

digital processing means for converting said time domain data into processed data;

means for comparing said processed data to an alarm threshold to determine an alarm condition;

means for creating a data record of said processed data;

means for adjusting said data record in accordance with a set of retention criteria corresponding to said alarm band;

means for comparing the memory availability, MA_j, of said storage means against a projected memory requirement PR_j and deleting certain of said stored data records; and

means for issuing an alarm when said memory availability is less than said projected memory requirement, PR_j.

20. The apparatus of claim 19 further comprising:

trigger means for comparing said time domain data to a trigger threshold value, and if said time domain data is greater than said trigger threshold value activating said digital processing means.

21. The apparatus of claim 20 further comprising:

means for remotely transferring said stored average spectrum to a central computer.

22. The apparatus of claim 21 wherein said means for remotely transferring said stored average spectrum comprises:

an infrared device for wireless communications between said central computer and said storage means.

23. The apparatus of claim 21 when said means for remotely transferring said stored average spectrum comprises:

a nonvolatile portion of said storage means, said nonvolatile portion being removable from said storage means and transferrable to said central computer.

24. The apparatus of claim 21 further comprising battery means for supplying power to said apparatus;

and

battery management control means for controlling utilization of said power.