Voice controlled vibration data analyzer systems and methods

• US 9,459,176 B2
• Filed: 10/26/2012
• Issued: 10/04/2016
• Est. Priority Date: 10/26/2012
• Status: Active Grant

• Current Assignee: Azima Holdings Incorporated (Fortive Corp.)
• Original Assignee: Azima Holdings Incorporated (Fortive Corp.)
• Inventors: Piety, Kenneth Ralph, Dahl, K. C.
• Primary Examiner(s): Lerner, Martin
• Application Number:
  US13/662,051
• Publication Number:
  US 20140122085A1
• Time in Patent Office: 1,439 Days
• Field of Search: 704/233, 704/251, 704/275, 73/18.2, 702/56, 702/122, 702/191
• US Class Current: 1/1
• CPC Class Codes: G01M 7/00 Vibration-testing of structures; Shock-testing of structures G01M9/00 takes precedence
• CPC Class Codes: G10L 2015/223 Execution procedure of a spoken command

Abstract

Embodiments of the present general inventive concept provide a voice controlled vibration data analyzer system, including a vibration sensor to detect vibration data from a machine-under-test, a data acquisition unit to receive the vibration data from the vibration sensor, and a control unit having a user interface to receive manual and audio input from a user, and to communicate information relating to the machine-under-test, the control unit executing commands in response to the manual or audio input to control the data acquisition unit and/or user interface to output an audio or visual message relating to a navigation path of multiple machines to be tested, to collect and process the vibration data, and to receive manual or audio physical observations from the user to characterize collected vibration data.

Claims

1. A portable, voice-controlled vibration data analyzer system configured to be carried by a user to detect vibration data from one or more vibration sensors coupled to one or more machines-under-test in a machine testing environment, the portable voice controlled system comprising:

a headset including an audio interface configured to receive verbal input from a user and to output verbal feedback to the user while vibration data is being detected from a vibration sensor, the verbal input including observation data from the user characterizing observed conditions of a particular machine-under-test, the headset being configured to suppress background noise to provide hearing protection and to separate the verbal input of the operator from the background noise;

a data acquisition unit to receive detected vibration data from the one or more vibration sensors;

a control unit in electronic communication with the vibration sensor, headset, and data acquisition unit, the control unit having a user interface to receive manual input from the user and to output visual feedback to the user via a visual interface, the control unit being configured to execute commands in response to manual or verbal input, the commands being configured to instruct the data acquisition unit to receive vibration data from the vibration sensor and to instruct the audio and visual interfaces to respectively output audio and visual messages relating to the detected vibration data, the control unit being further configured to process the vibration data into assembled data packets comprising a collected set of vibration data, observation data, and information identifying a measurement location of the detected vibration data, and to selectively output verbal and visual feedback data to the audio and visual interfaces, respectively, based on the data packets, while vibration data is being detected, the control unit comprising;

a command recognition engine configured to store a plurality of available verbal commands corresponding to a plurality of operational states of the system such that one or more verbal commands that would be available in one operational state are not available in a different operational state where only those commands that are predetermined to be reliable in a particular machine testing environment defined by varying levels and frequencies of ambient noise are included in the plurality of available verbal commands;

a speech recognition engine configured to test received verbal input against available verbal commands of a particular operational state, and to determine if the received verbal input is recognized as a valid verbal command; and

a training module configured such that the user can select via the audio or visual interface to (i) choose from a list of alternative available commands that are predetermined to be reliable in the particular machine testing environment, or (ii) define a substitute command, when a particular verbal input is not recognized as an available command, and to selectively store the substitute command personalized to a specific user, dynamically modifying the visual interface to reflect the changes in the command syntax.

2. The voice-controlled vibration data analyzer of claim 1, wherein the control unit executes commands in response to the manual or verbal input to locate a particular machine and measurement location using identification (ID) tag numbers, to enter or measure a predetermined operational parameter of the machine-under-test, and/or to take a photograph, audio recording, and/or visual recording of the machine-under-test or operating environment thereof.

3. The voice-controlled vibration data analyzer of claim 1, further comprising an automated analysis system selectable by the user via the user interface, the automated analysis system being configured to compare the detected vibration data against baseline values corresponding to the particular machine-under-test based on deviations of the detected vibration data against the baseline values, and provide visual and verbal output indicating the severity of the measured deviations.

4. The voice-controlled vibration data analyzer of claim 3, wherein the automated analysis module in the control unit is configured as an expert system to review the detected vibration values corresponding to the particular machine-under-test such that the expert system identifies a suspected fault condition based on deviations of the detected vibration data against the baseline values, and identifies one or more most likely faults, their respective severities, and recommended actions using both audible and visual outputs as feedback to the operator.

5. The voice-controlled vibration data analyzer of claim 4, wherein the expert system is configured to suggest one or more additional data collection tests to verify the accuracy of an analysis from among a plurality of different measurement collection setups based on the suspected fault condition.

6. The voice-controlled vibration data analyzer of claim 1, wherein the control unit and the data acquisition unit are formed as a separate unit.

7. A portable, voice-controlled vibration data analyzer configured to be carried by a user to detect vibration data from a vibration sensor coupled to a machine-under-test, the analyzer comprising:

a data acquisition unit to receive detected vibration data from the vibration sensor; and

a control module having a touch-visual user interface to receive and display information relating to machine conditions, and an audio user interface to receive and communicate information relating to machine conditions such that the control module controls operation of both user interfaces simultaneously to execute commands to be performed by the data acquisition unit in response to an audio input to the audio user interface without a manual input to the touch-visual user interface, to locate a desired machine among multiple machines along a predetermined collection route, to enable predefined and elective modes of data collection, to log results from a user relating to physical observations of the machine-under-test into observation data, and to determine whether additional measurements are needed and whether to collect additional vibration data, the control unit being configured to process vibration data into assembled data packets including one or more of a collected set of vibration data, observation data, and information identifying a measurement location of the machine-under-test, and to selectively output verbal and visual feedback data to the audio and visual interfaces, respectively, based on the data packets;

wherein the control module includes a training module configured such that the user can select via the audio user interface or touch-visual user interface to (i) choose from a list of alternative commands that are predetermined to be reliable in the particular machine testing environment, or (ii) define a substitute command, when a particular verbal input is not recognized as an available command, and to selectively store the substitute command personalized to a specific user;

dynamically modifying the touch-visual interface to reflect the changes in the command syntax.

8. The vibration data analyzer of claim 7, further comprising a wired or wireless headset including an audio interface configured to receive verbal input from a user and to output verbal feedback to the user, the headset being configured to suppress background noise to provide hearing protection and to selectively differentiate the verbal input of the operator from the varying frequencies and amplitudes of the noise sources emanating from different locations in the test environment.

9. The voice-controlled vibration data analyzer of claim 7, wherein the audio user interface is configured to receive verbal input from the user, including verbal instructions and verbal notations from the operator.

10. The voice-controlled vibration data analyzer of claim 9, wherein the touch-visual interface is configured to receive manual instructions from the user and to display information relating to the health of the machine-under-test.

11. The voice-controlled vibration data analyzer of claim 10, wherein the vibration sensor is configured to interact with the machine-under-test in order to gather the vibration data relative to the machine-under-test, the vibration sensor being connected to the data acquisition unit by wire.

12. The voice-controlled vibration data analyzer of claim 7, wherein the control module includes:

a speech recognition engine to accept and recognize a voice input and to filter the voice input from other noise signals received by the audio user interface;

a command recognition engine to accept and recognize verbal instructions and manual instructions respectively via the audio user interface and touch-visual user interface, the command recognition engine comparing verbal input to a lexicon of known verbal instruction terms and to designate a verbal input as a verbal instruction when the verbal input corresponds to one of the known verbal instruction terms; and

a controller engine to control the collection of data, the display of data, the evaluation of the quality of the data and the health of the machine-under-test, the communication of data and machine-under-test status, the selection of operational modes, in response to the verbal instructions, and the selection of active lexicon commands depending on the operational state.

13. A method of collecting vibration data from a machine-under-test using the vibration data analyzer of claim 7, the method comprising:

inputting a first verbal command from a user to the control module to instruct the data acquisition unit to receive vibration data from the vibration sensor, without the user manually touching the control unit;

outputting an audio message from the control module to the user to communicate information relating to received vibration data, without the user having to visualize the control module; and

inputting a second verbal command from the user to the control module to instruct the control module to output an audio message relating to a navigation path of multiple machines to be tested, and to record an audible observation from the user about a condition of the machine-under-test.

14. The voice-controlled vibration data analyzer of claim 7, wherein the control module includes a speech recognition engine configured to test received verbal input against available verbal commands of a particular operational state, and to determine if the received verbal input is recognized as a valid verbal command, to record verbal input regarding a variety of observed physical conditions and identify the mechanical component and the specific location of the observed conditions using simple one or two word commands.

15. The voice-controlled vibration data analyzer of claim 14, wherein the verbal commands control the acquisition of audio and photographic recordings to document observed conditions.

16. The voice-controlled vibration data analyzer of claim 7, wherein the control module includes an automated analysis system selectable by the user via the audio user interface or touch-visual user interface, the automated analysis system being configured to compare the detected vibration data against baseline values corresponding to the particular machine-under-test based on deviations of the detected vibration data against the baseline values, and provide visual and verbal output indicating the severity of the measured deviations.

17. The voice-controlled vibration data analyzer of claim 7, wherein the automated analysis module in the control module is configured as an expert system to review the detected vibration values corresponding to the particular machine-under-test such that the expert system identifies a suspected fault condition based on deviations of the detected vibration data against the baseline values, and identifies one or more most likely faults, their respective severities, and recommended actions using both audible and visual outputs as feedback to the operator.

18. The voice-controlled vibration data analyzer of claim 17, wherein the expert system is configured to recommend one or more additional data collection tests to confirm or deny the existence of the suspected fault condition.

19. The voice-controlled vibration data analyzer of claim 7, wherein the control module is configured to selectively initiate audio and/or photographic recordings according to a command entered through the audio user interface or touch-visual user interface.