Process and system for analyzing fault log data from a machine so as to identify faults predictive of machine failures

• US 6,622,264 B1
• Filed: 11/22/1999
• Issued: 09/16/2003
• Est. Priority Date: 10/28/1999
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Roddy, Nicholas E., Bliley, Richard G.
• Primary Examiner(s): Beausoliel, Robert
• Assistant Examiner(s): CHU, GABRIEL L
• Application Number:
  US09/447,064
• Time in Patent Office: 1,394 Days
• Field of Search: 714/26, 714/33, 714/37, 714/45, 714/25, 706/51, 706/61, 706/50, 706/58
• US Class Current: 714/26
• CPC Class Codes: G06F 11/2257 using expert systems

Abstract

A process for analyzing fault log data from a machine is provided. The process allows for downloading new fault log data from the machine. The process further allows for retrieving prior fault log data of the machine. The prior fault log data may be obtained during an earlier download relative to a present download of new fault log data. A comparing step allows for comparing the new fault log data against the prior fault log data, and an adjusting step allows for adjusting any repair recommendations for the earlier download of fault log data based upon the comparison of the new fault log data and the prior fault log data.

Claims

1. A process for analyzing fault log data from a machine so as to identify respective faults and/or fault combinations predictive of machine malfunctions, the process comprising:

a) downloading new fault log data from the machine;

b) retrieving prior fault log data of the machine, the prior fault log data obtained during an earlier download relative to the download of step a), wherein the earlier download of fault log data comprises the last download executed prior to the download of step a);

c) comparing the new fault log data against the prior fault log data, wherein the comparing step comprises determining respective occurrences of any new faults since the last download;

d) classifying any new faults in a respective classification selected from the group consisting of active or inactive faults;

e) executing expert analysis on any faults classified as inactive;

f) assigning a respective repair action to any faults classified as active; and

g) adjusting any repair recommendations for the earlier download of fault log data based upon the comparison of the new fault log data and the prior fault log data.

2. The process of claim 1 wherein the comparing step comprises determining respective occurrences of any repeat faults.

3. The process of claim 2 wherein the comparing step comprises determining whether any repeat faults are related to one another.

4. The process of claim 1 wherein the comparing step comprises determining whether any new faults are related to one another.

5. The process of claim 1 wherein the repair action is based upon matching respective repair entries in an externally-derived file of repairs, each fault being associated with at least one or more repairs.

6. The process of claim 1 wherein the machine is a locomotive.

7. A system for analyzing fault log data from a machine so as to identify respective faults and/or fault combinations predictive of machine malfunctions, the system comprising:

means for downloading new fault log data from the machine;

means for retrieving prior fault log data of the machine, the prior fault log data obtained during an earlier download relative to a present download of new fault log data, wherein the earlier download of fault log data comprises the last download executed prior to the present download of new fault log data;

means for comparing the new fault log data against the prior fault log data;

means for determining respective occurrences of any new faults since the last download;

means for classifying any new faults in a respective classification selected from the group consisting of active or inactive faults;

means for executing expert analysis on any faults classified as inactive;

means for assigning a respective repair action to any faults classified as active; and

means for adjusting any repair recommendations for the earlier download of fault log data based upon the comparison of the new fault log data and the prior fault log data.

8. The system of claim 7 further comprising means for determining respective occurrences of any repeat faults.

9. The system of claim 8 further comprising means for determining whether any repeat faults are related to one another.

10. The system of claim 7 further comprising means for determining whether any new faults are related to one another.

11. The system of claim 7 wherein the repair action is based upon matching respective repair entries in an externally-derived file of repairs, each active fault being associated with at least one or more repairs.

12. The system of claim 7 wherein the machine is a locomotive.

13. A process for developing a kit that enables respective users to analyze fault log data from a machine so as to identify respective faults and/or fault combinations predictive of machine malfunctions, the process comprising:

a) downloading new fault log data from the machine;

b) retrieving prior fault log data of the machine, the prior fault log data obtained during an earlier download relative to the download of step a), wherein the earlier download of fault log data comprises the last download executed prior to the download of step a);

c) comparing the new fault log data against the prior fault log data;

d) classifying any new faults in a respective classification selected from the group consisting of active or inactive faults;

e) executing expert analysis on any faults classified as inactive;

f) assigning a respective repair action to any faults classified as active; and

g) adjusting any repair recommendations for the earlier download of fault log data based upon the comparison of the new fault log data and the prior fault log data.

14. The process of claim 13 wherein the comparing step comprises determining respective occurrences of any new faults since the last download.

15. The process of claim 13 wherein the comparing step comprises determining respective occurrences of any repeat faults.

16. The process of claim 15 wherein the comparing step comprises determining whether any repeat faults are related to one another.

17. The process of claim 13 wherein the comparing step comprises determining whether any new faults are related to one another.

18. The process of claim 13 wherein the repair action is based upon matching respective repair entries in an externally-derived file of repairs, each active fault being associated with at least one or more repairs.

19. The process of claim 13 wherein the fault log data further comprises snapshot observations of predetermined operational parameters from the machine.

20. The process of claim 13 wherein the machine is a locomotive.

21. A computer program product comprising a computer-usable medium having a computer-readable code therein for executing the steps comprising:

a) downloading new fault log data from the machine;

b) retrieving prior fault log data of the machine, the prior fault log data obtained during an earlier download relative to the download of step a), wherein the earlier download of fault log data comprises the last download executed prior to the download of step a);

c) comparing the new fault log data against the prior fault log data;

d) classifying any new faults in a respective classification, wherein the respective classification of new faults is selected from the group consisting of active or inactive faults;

e) classifying any new faults in a respective classification including a classification of active faults; and

f) assigning a respective repair action to any faults classified as active.

22. A process for analyzing fault log data from a machine to identify respective faults and/or fault combinations predictive of machine malfunctions, the process comprising:

a) downloading new fault log data from the machine;

b) retrieving prior fault log data of the machine, the prior fault log data obtained during an earlier download relative to the download of step a);

c) comparing the new fault log data against the prior fault log data, wherein the comparing step comprises determining respective occurrences of any new faults since the earlier download;

d) classifying any new faults in a respective classification, including a classification of active faults;

e) assigning a respective repair action to any faults classified as active; and

f) adjusting any repair recommendations for the earlier download of fault log data based upon the comparison of the new fault log data and the prior fault log data.

23. The process of claim 22 wherein the earlier download of fault log data comprises the last download executed prior to the download of step a).

24. The process of claim 22 wherein the comparing step comprises determining respective occurrences of any repeat faults.

25. The process of claim 22 wherein the comparing step comprises determining whether any repeat faults are related to one another.

26. The process of claim 22 wherein the comparing step comprises determining whether any new faults are related to one another.

27. The process of claim 26 wherein the respective classification of new faults further includes inactive faults.

28. The process of claim 27 further comprising a step of executing expert analysis on any faults classified as inactive.

29. The process of claim 22 wherein the repair action is based upon matching respective repair entries in an externally-derived file of repairs, each fault being associated with at least one or more repairs.

30. A system for analyzing fault log data from a machine so as to identify respective faults and/or fault combinations predictive of machine malfunctions, the system comprising:

a processor configured to download new fault log data from the machine;

a processor configured to retrieve prior fault log data of the machine stored in a database, the prior fault log data obtained during an earlier download relative to a present download of new fault log data;

a processor configured to determine respective occurrences of any new faults since the earlier download;

a processor configured to classify any new faults in a respective classification, including a classification of active faults;

a processor configured to assign a respective repair action to any faults classified as active;

a processor configured to compare the new fault log data against the prior fault log data; and

a processor configured to adjust any repair recommendations for the earlier download of fault log data based upon the comparison of the new fault log data and the prior fault log data.