Automated prognostics systems and methods

• US 9,791,352 B2
• Filed: 09/17/2014
• Issued: 10/17/2017
• Est. Priority Date: 09/17/2014
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Patrick, Romano, Vittal, Sameer, Reimann, Johan Michael
• Primary Examiner(s): Le, John H
• Application Number:
  US14/488,669
• Publication Number:
  US 20160076976A1
• Time in Patent Office: 1,126 Days
• Field of Search: 702 34, 702182, 702 33, 702 36, 701100, 703 2, 706 14
• CPC Class Codes: G01M 15/00 Testing of engines
• CPC Class Codes: G01M 99/005 Testing of complete machines, e.g. washing-machines or mobile phones testing of machine parts G01M13/00; testing of electric apparatus or components G01R31/50
• CPC Class Codes: G01M 99/008 by doing functionality tests
• CPC Class Codes: G05B 23/0224 Process history based detection method, e.g. whereby history implies the availability of large amounts of data
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06

Abstract

An automated prognostics system includes a sensor system configured to obtain measurement data by monitoring one or more parameters at one or more locations on each of one or more movable components of an object when the object is subjected to a first mode of operation. The system also includes a computing device having an input interface and a processor. The input interface receives input information such as spatial coordinates information associated with the one or more locations, the measurement data obtained by the sensor system, operational data associated with the first mode of operation, and structural data associated with the object. The processor processes the input information and generates a prognostics report on at least a first component of the one or more movable components, the prognostics report including at least one of a failure prognostic or a likelihood-of-failure prognostic of the first component.

Claims

1. A method to assess one or more movable components of a turbine, the method comprising:

subjecting the turbine to a first mode of operation;

using a sensor system to obtain measurement data by monitoring one or more parameters at a plurality of locations on each of the one or more movable components when the turbine is subjected to the first mode of operation;

providing to a computing device, input information comprising spatial coordinates information associated with the plurality of locations, the measurement data obtained by the sensor system, operational data associated with the first mode of operation, and structural data associated with the turbine; and

combining the measurement data and the spatial coordinates information to generate a synthesized representation of at least a first component in the one or more movable components, the synthesized representation of the at least a first component providing a visual indication of one of a failure or a likelihood-of-failure in at least one area when the failure or the likelihood-of-failure is present in the at least one area.

2. The method of claim 1, further comprising:

processing the input information in the computing device to generate at least one of a first diagnostics report or a first prognostics report on at least the first component, the at least one of the first diagnostics report or the first prognostics report comprising at least one of a failure report, a failure prognostic, or a likelihood-of-failure prognostic of at least a portion of the first component.

3. The method of claim 2, wherein processing the input information data to generate the at least one of the first diagnostics report or the first prognostics report comprises using the synthesized representation of the first component.

4. The method of claim 1, wherein the computing device generates a prediction that one of the first component or a second component is an expected first-to-fail component.

5. The method of claim 4, wherein the prediction comprises a numerical probability of the one of the first component or the second component being the expected first-to-fail component, and further comprises an indication of an expected time-of-failure of the one of the first component or the second component when the turbine is continually subjected to the first mode of operation.

6. The method of claim 1, wherein the one or more movable components comprise a turbine blade, and wherein the computing device generates a statistical probability of failure of a portion of the turbine blade when the turbine is continually subjected to the first mode of operation.

7. The method of claim 6, wherein the computing device generates a revised statistical probability of failure of the portion of the turbine blade if the first mode of operation were to be changed to a second mode of operation.

8. The method of claim 1, wherein the operational data comprises a load profile, and wherein the structural data comprises data indicative of a structural condition of at least the first component prior to subjecting the turbine to the first mode of operation.

9. The method of claim 8, wherein the load profile comprises at least one of a stress imposed on the turbine during the first mode of operation, a temperature associated with the first mode of operation, or an amount of power consumed by the turbine during the first mode of operation.

10. The method of claim 1, further comprising:

subjecting the turbine to a second mode of operation;

using the sensor system to obtain measurement data by monitoring the one or more parameters at the plurality of locations on each of the one or more movable components when the turbine is subjected to the second mode of operation;

providing to the computing device, imputed data comprising the measurement data obtained by subjecting the turbine to the first mode of operation, operational data associated with the first mode of operation, and structural data associated with the turbine after subjecting the turbine to the first mode of operation; and

processing the imputed data and the measurement data obtained when the turbine is subjected to the second mode of operation, to generate at least one of a diagnostics report or a prognostics report on the first component, the at least one of the diagnostics report or the prognostics report comprising at least one of a failure prognostic or a likelihood-of-failure prognostic of the first component due to prior subjecting of the turbine to the first mode of operation.

11. A system for assessing one or more movable components of a turbine, the system comprising:

a sensor system configured to obtain measurement data by monitoring one or more parameters at a plurality of locations on each of one or more movable components of the turbine when the turbine is subjected to a first mode of operation;

a computing device comprising;

an input interface configured to;

receive input information comprising spatial coordinates information associated with the plurality of locations, the measurement data obtained by the sensor system, operational data associated with the first mode of operation, and structural data associated with the turbine; and

a processor configured to;

combine the measurement data and the spatial coordinates information to generate a synthesized representation of at least a first component in the one or more movable components, the synthesized representation of the at least a first component providing a visual indication of one of a failure or a likelihood-of-failure in at least one area when the failure or the likelihood-of-failure is present in the at least one area.

12. The system of claim 11, wherein the computing device is further configured to process the input information received through the input interface and generate therefrom, at least one of a diagnostics report or a prognostics report on at least the first component of the one or more movable components, the at least one of the diagnostics report or the prognostics report comprising at least one of a failure report, a failure prognostic, or a likelihood-of-failure prognostic.

13. The system of claim 12, wherein the computing device is further configured to use the synthesized representation of the at least one of the one or more movable components to generate the at least one of the diagnostics report or the prognostics report.

14. The system of claim 11, wherein the computing device is configured to generate a prediction that one of the first component or a second component is an expected first-to-fail component.

15. The system of claim 11, wherein the one or more movable components comprise a turbine blade, and wherein the computing device is configured to:

generate a first statistical probability of failure of a portion of the turbine blade when the turbine is continually subjected to the first mode of operation; and

generate a revised statistical probability of failure of the portion of the turbine blade if the first mode of operation were to be changed to a second mode of operation.

16. A non-transitory computer-readable storage medium containing instructions executable by a computer for performing operations comprising:

receiving measurement data obtained by monitoring one or more parameters at a plurality of locations on at least a first component of one or more movable components of a turbine, when the turbine is subjected to a first mode of operation;

receiving spatial coordinates information associated with the plurality of locations; and

combining the measurement data and the spatial coordinates information to generate a synthesized representation of the first component, the synthesized representation of the first component providing a visual indication of one of a failure or a likelihood-of-failure in at least one area when the failure or the likelihood-of-failure is present in the at least one area.

17. The non-transitory computer-readable storage medium of claim 16, containing further instructions executable by the computer for performing operations comprising:

receiving operational data associated with the first mode of operation;

receiving structural data associated with the turbine; and

processing at least one of the measurement data, the operational data, and the structural data and generate therefrom, a prognostics report on at least a first component of the one or more movable components, the prognostics report comprising at least one of a failure prognostic or a likelihood-of-failure prognostic, of the first component.

18. The non-transitory computer-readable storage medium of claim 17, containing further instructions executable by the computer for performing operations comprising:

using the synthesized representation of the at least one of the one or more movable components to generate the prognostics report.

19. The non-transitory computer-readable storage medium of claim 16, containing further instructions executable by the computer for performing operations comprising:

generating a prediction that one of the first component or a second component is an expected first-to-fail component.

20. The non-transitory computer-readable storage medium of claim 16, wherein the one or more movable components comprises a turbine blade, and further comprising instructions executable by the computer for performing operations comprising:

generating a first statistical probability of failure of a portion of the turbine blade when the turbine is continually subjected to the first mode of operation; and

generating a revised statistical probability of failure of the portion of the turbine blade if the first mode of operation were to be changed to a second mode of operation.