PROCESS MAPPING AND MONITORING USING ARTIFICIAL INTELLIGENCE
The disclosure describes a system for the advanced delivery of information. In some embodiments, the system creates a display in response to an alarm. In some embodiments, the information on the display is a function of attribute mapping and/or analysis performed by the system. The system uses one or more of manual links, statistical analysis, correlations, maintenance data, and/or historical data as tools during determination of what to display according to some embodiments. In some embodiments, the system uses one or more of these tools in conjunction with one or more of process simulators, artificial intelligence, machine learning, and/or real process feedback in the analysis to determine what to display to a user during an emergency and/or an anomalous event.
This application claims the benefit of and priority to U.S. Provisional Application No. 62/806,572, filed Feb. 15, 2019, entitled “System and Server for Asset Search-Based Visualization of Alarms with Dynamic Grouping”, the entire contents of which are incorporated herein by reference.
BACKGROUNDDuring times of emergency, quick action is difference between a near miss and a catastrophe. Often times, alarms can come in seemingly all at once, and in an unrelated fashion. Prioritizing those alarms can be a time-consuming task; the time spent on sorting and displaying alarm data in a coherent fashion can be the difference between success and failure.
In addition, some alarms only occur at remote locations are do not have a direct connection to an integrated monitoring system. In addition, some alarms are manually triggered by human intervention. A current problem in industry is missed abnormal situations or product review due to distractions.
The current state of the prior art is one where a user is responsible for building displays to provide reports on one or more assets. Asset information for the report can include industrial system assets such as sensors and quality assurance measurement equipment, but can also include any other parameter that can be reported in a visualized form, such as market trends or traffic patterns. Prior art report visualizations are not adaptable to different display types. Viewing the same information designed for a screen on a cell phone, for example, results in the graphs becoming too small to be intelligible.
The prior art also requires that all links between the asset information used in reports be performed manually. For example, in the prior art a graph representing correlation between two attributes of the same or different assets needs to be manually created, saved, and selected for display. A typical correlation graph in the prior art is obtained by manually selecting two sets of raw data, and then plotting each on a different axis to visually determine if there is relationship (i.e., inspect the display to determine if there is a slope change in a fitted line). If in the case of an emergency the correlation graph does not exist, precious time must be taken in order to create the graph. Even if the graph does exist, it is most likely stored in a folder that is specific to the user, and a search for the graph, or a report including the graph, can be a fruitless undertaking, resulting in more wasted time. In the case of industries such as semiconductors, for example, a single hour wasted can result in millions of dollars in lost production capability.
The prior art uses alarms to alert personnel when one or more asset parameters exceed an alarm limit. These alarms are usually generated from a monitoring a system in the form of flashing text, sometimes accompanied by the setpoint and exceeded value. In the prior art, a user must then log onto a computer, load the monitoring system, and then manually pull the “tags” associated with each alarm. These tags are then loaded into the manually configured graphs and/or reports for visual analysis. Statistical analysis requires a manual setup of more graphs and reports. In the case of an alarm for a measurement tool, there could be numerous different types of equipment (e.g., shredders, conveyors, ovens, robotics) between measurement nodes. In the prior art, a user must determine what equipment is between the nodes, which attributes to graph, and try to determine what the root cause for the anomaly and what actions to take in response.
Therefore, there is a need for a system that automatically monitors production environments and generates a display with items generated from relevant information from enormous amounts of asset data (e.g., tags) stored on a database, such that timely action can be taken to prevent the loss of profit.
SUMMARYSome embodiments disclosed herein include a system for improving the delivery of emergency information. In some embodiments, a computer processor reads instructions stored on a non-transitory processor readable medium (i.e., computer code stored on computer memory). In some embodiments, the instructions are configured and arranged to read asset data from a database. In some embodiments, assets can include industrial system assets such as sensors and quality assurance measurement equipment. In some embodiments, asset data can also include any other asset parameter that can be reported using a picture, graph, table, and/or link form: monitors for market trends or traffic patterns are non-limiting examples of such assets. In some embodiments, asset data is a digital representation of an analog or digital signal received from and asset. In some embodiments, one or more control limits and/or spec limits are associated with a parameter of the asset data. In some embodiments, the parameter of the asset data is a sensor “tag” that has delivered sensor data to the system for storage in the database. In some embodiments, the database is a local database located on-site; in some embodiments, the database is a historian database that also includes the processor and non-transitory computer readable medium. In some embodiments, the system generates an alarm when one or more control limits and/or spec limit are exceeded.
In some embodiments, aspects of the system include a novel way of presenting relevant information associated with an alarm. In some embodiments, the system is configured and arranged to read asset data from a database; compare the asset data to one or more alarm limits; display alarm information when a primary asset's parameter exceeds the one or more alarm limits; and determine secondary information to display in conjunction with the alarm.
In some embodiments, reading asset data includes reading the asset data from not only the alarming asset's tag, but tags associated with the asset. In some embodiments, the system comprises instructions to perform large scale statistical analysis on some or all tag data to determine relationships between one or more assets (i.e., if the inputs/outputs of an asset are dependent on the input/output of another asset). In some embodiments, the system uses an assets attributes to perform the statistical analysis.
In some embodiments, attributes of an asset can include an asset's measurement parameters (i.e., tags) such as time, temperature, pressure, power, amps, voltage, flowrate, and/or any measurement that can be delivered visually or through an electrical signal. In some embodiments, an asset's attributes can include color, texture, age, material location, size, shape, mass, density, failure specifications, or any other physical characteristic of an asset. In some embodiments, an asset's attributes can be the effect an input/output of the asset has on an upstream and/or downstream asset and/or process. In some embodiments, any or all of an asset's attributes are used in the system's statistical and/or presentation analysis. In some embodiments, the system uses an attribute map that includes one or more links between a primary asset and a secondary asset to determine which attributes should be included in the analysis, prediction, and/or information to display. In some embodiments, the attribute map is used by the system to determine the information to display in conjunction with an alarm.
In some embodiments, the statistical analysis can be performed by the system on-demand, continuously, intermittently, and/or some combination thereof. In some embodiments, statistical analysis is performed by the selection of one or more inputs on a graphical user interface (GUI). In some embodiments, when a user chooses a link and/or breadcrumb, statistical analysis is performed for a particular asset and/or a hierarchy of assets. In some embodiments, the system executes conventional known statistical analysis techniques and/or algorithms. In some embodiments, the system executes proprietary statistical analysis techniques and/or algorithms. In some embodiments, the system automatically generates one or more displays including graphs, charts, tables, reports, root cause analysis, suggested action items, and/or countermeasures. As used herein, a reference to a system generated item and/or information for display is also a reference to an icon, breadcrumb, and/or link that leads to a different display comprising the item and/or information; generates that item and/or information on the current display; expands, highlights, and/or jumps to a portion of the display with the item and/or information.
In some embodiments, the system uses identified asset attribute dependencies to identify inputs to the process that may be the root cause of the alarm. For example, in some embodiments, multiple alarms are received from different areas of a plant: in response the system performs a root cause analysis and determines that that parameter that has alarmed at a downstream asset step is correlated to an equipment parameter that the system has determined causes a product defect (i.e., an upstream equipment and/or setpoint problem caused a defective output that is now the input to the downstream step, causing an equipment malfunction resulting in an alarm). A display according to some embodiments presented herein is generated with relevant alarm information. In some embodiments, precious time is saved by the system prioritizing the alarms for display in the order that they need to be addressed. In some embodiments, precious time is saved by the system automatically providing one or more of: a report that explains why the alarm(s) have occurred; evidence and historical data (i.e., past actions taken for similar events) to support the conclusion; a list of action items for how to most efficiently address the problem; historical asset data displayed as a graph (e.g., bar, pie, pareto) and/or report; and/or maintenance reports.
In some embodiments the system includes a cloud based or cloud/on-site hybrid historian system, collectively referred to herein as a historian and/or a historian database. In some embodiments, the use of a historian allows for the centralization of asset and/or process data obtained from multiple locations (e.g., industrial plants, fleet vehicles, business servers, and/or any source of data). In some embodiments, centralization allows for the system to perform one or more analyses discussed above and/or throughout this disclosure using data from some and/or all of the multiple locations. In some embodiments, this improves system accuracy by providing a larger dataset for analysis. In some embodiments, a larger dataset improves the accuracy of proprietary and/or conventional artificial intelligence, machine learning, and/or deep learning algorithms (collectively referred to herein as AI) that is used in conjunction with the statistical analysis and relevant information determination as described above.
In some embodiments, AI is used in one, some, or all analysis and/or embodiments presented in this disclosure. In some embodiments, AI is used to determine the most relevant items to display, and/or the type of display used to convey the information (e.g., a chart, graph, report, link, etc.). In some embodiments, algorithms that do not comprise AI executes one or more actions described herein. In some embodiments, the system uses processor readable instructions stored on memory that when read by a processor implement one or more aspects of the system. Throughout this disclosure the use of the phrases that include “the system,” “the system determines,” “the system determines,” “the system executes,” “the system generates,” “the system displays,” “the system compares” and/or similar language, includes the use of AI and/or non-AI algorithms in execution of the action and/or step performed by “the system.”
In some embodiments, the system can automatically process and display items and/or information specific to a user. In some embodiments, the system identifies the specific user by login identification, facial recognition, maintenance records, approvals, and/or any stored data linking a user to a particular role in an organization. In some embodiments, each specific user receives a tailored alarm display based on his/her role in the organization. In some embodiments, the system uses AI in conjunction with stored data to determine relevant items/information to display based on an individual's role. In some embodiments, the system uses an algorithm that does not include AI to execute an analysis on stored data to determine relevant items/information to display based on an individual's role. For example, in some embodiments specific users can include a manager, a process engineer, and an equipment technician. In some embodiments, the process engineer receives an alarm list that comprises product measurements, a technician receives alarms that relate to equipment sensors, and the manager receives an alarm list that includes both product measurements and sensor data: those of ordinary skill would recognize that any combination of items/information can be conveyed as desired.
In some embodiments, the system determines the content and/or format for the display. In some embodiments, a “display” as used herein is defined as an electronic display configured to present a visual representation of information. For example, in some embodiments, the system reads asset data from one or more databases. The system then compares the asset data to one or more alarm limits. In some embodiments, the comparison is done regularly and the results stored in the database. When a primary asset's parameter exceeds the one or more alarm limits, an alarm is generated according to some embodiments. As a result, in some embodiments, the system determines information to display in conjunction with a visual representation of the alarm. As described above, the system executes various algorithms and analysis to determine the best information content to display for a particular alarm and/or user.
For example, if a robot alarms because it's sensors do not detect the presence of an expected object, information about an exit counter sensor from a previous processing step may be included with the alarm display according to some embodiments. When, during analysis, the system determines the exit counter accounted for the missing object, the system determines that the missing object must have been lost somewhere between the two processing steps. In some embodiments, the system can review maintenance history and determine that this error is common with several root causes, such as a broken conveyor belt, a malfunctioning actuator, and/or some operator error. In some embodiments, these each of these root causes may have occurred and been recorded in the system and/or fed to the system at different facilities spread across different states. In some embodiments, the system collects action items and/or standard operating procedures that are needed to fix the issue. In some embodiments, the system displays one or more of the alarm, the root cause list (several in this case), and a link to the action items and/or standard operating procedures. As evident from this non-limiting example, massive amounts of precious production time can be saved, as even someone unfamiliar with the process could implement and/or start the implementation of the solution.
In some embodiments, the system selects the information (primary information, secondary information, etc.) to display based on one or more attributes of the primary asset (e.g., time, temperature, pressure, power, amps, voltage, flowrate, etc.). In some embodiments, the information. For example, as is known in the art, pressure and temperature share a direct relationship. Therefore, when a pressure alarm occurs, the system automatically provides the user with both a temperature and pressure time series chart (of course, other types of information displays are possible) according to some embodiments. In some embodiments, if the system determines that the alarm is often caused by a faulty sensor that delivers a power spike at failure, the system can automatically include that information in the form of a sensor line graph and/or in the root cause analysis, as a non-limiting example.
In some embodiments, the system comprises a process model simulator. In some embodiments, the simulator optimizes 2D and/or 3D model component performance. In some embodiments, the simulator improves 2D and/or 3D model design, and offers operational analysis and/or performing engineering studies. For example, in some embodiments, the simulator is designed to perform rigorous heat and material balance calculations for a wide range of processes.
In some embodiments, AI is trained using simulator data, production data, and/or a combination of simulator data and/or production data. For example, during simulation of abnormal conditions (e.g., during training and/or new facility planning), the system uses the simulated trends to train the AI model for prediction purposes according to some embodiments. In some embodiments, the system AI is trained on which process parameters correlated to each other by randomizing simulator values and performing analysis on the result (e.g., regression analysis). In some embodiments, system analysis performed in simulation is feed to an AI training model to improve the model's accuracy. In some embodiments, this novel use of a simulator to “pre-train” an AI model allows the system to predict trend conditions never actually recorded in a real system. In some embodiments steps labeled in continuous simulated trends are feed to the AI during training so that those steps can be excluded from the model and/or used in a different model and/or analysis.
In some embodiments, the system allows the user to do one or more of the following: design new processes; evaluate alternate model configurations; modernize or revamp existing models; assess and document compliance within environmental regulations; troubleshoot and debottleneck plant processes; monitor, optimize, and/or improve plant yields and/or profitability; all of which are non-limiting examples of the system's capability. In some embodiments, the system uses the simulator to predict the effects of an alarm on one or more parts of a process. In some embodiments, the prediction is done at the time of the alarm. In some embodiments, the prediction is done during or after an alarm has occurred. In some embodiments, the system uses the simulator to establish correlation links between asset attributes. In some embodiments, the correlation links created during simulations are used to create an attribute map. In some embodiments, simulations are used to create importance rankings used to determine information to display to a user. In some embodiments, simulations are run manually. In some embodiments, simulations are run by system algorithms continuously, intermittently, and/or in response to alarms. In some embodiments, simulations are run by system AI continuously, intermittently, and/or in response to alarms. In some embodiments, actual response data is used by the system to improve prediction modeling.
In some embodiments, the system comprises capability for add-on modules. In some embodiments, add-on modules comprise modules designed to be integrated into the system. In some embodiments, the system includes application programming interfaces (i.e., APIs) that work together with third-party software and/or system software. In some embodiments, in some embodiments, the system includes one or more programming applications (APPs), such as conventional and/or proprietary AI APPs, for example. In some embodiments, third-party software comprises licensable add-ons. In some embodiments, add-on modules extend the functionality of the system in various ways.
In some embodiments, the system comprises operation training. In some embodiments, a copy of the entire model can run a process using the simulator. In some embodiments, process changes can be made in the simulation without affecting the real process model. In some embodiments, the system can be used for one or more of the following: train operators on the user interface, run drills, provide training for new equipment and/or system upgrades, and/or any other type of training need. In some embodiments, training simulation models can be integrated into the system as the actual control interface for a factory process. In some embodiments, personnel are trained on AI monitoring predictions using the simulator.
In some embodiments, the system displays new information and/or reconfigures information when a user changes displays. In some embodiments, the information and/or format of the display is customized by the system for a display's screen size. For example, in some embodiments, if a user pulls up a display comprising alarm information on a first display, a first information format is used to display the information. If the alarm information is pulled up on a second display, a second information format is used to display the same information according to some embodiments. In some embodiments, the different format is due to the second display having a visualization area that is different from the first display. In addition, in some embodiments, there can be more or less information presented to a user on the second display, based on the available visualization area as determined by the system. For example, if a user is viewing alarm data from a piece of equipment on a portable computer, such as a cell phone, for example, then the user may see one or more equipment control charts with the alarm points highlighted, a list of alarms, and breadcrumbs at the top of the browser that leads to a hierarchy of equipment and/or shows a link to previously viewed items. When the user accesses the same alarm data from a larger monitor, such as a desktop monitor or television screen, the same information that was presented on the portable computer is shown, and additionally, a process flow diagram can be displayed, where each item in the process flow has countermeasure links that comprise instruction for how to fix the alarm and fix the root cause.
In some embodiments, if a user is viewing the information in a window (e.g., a browser window) and that window is resized, the system automatically determines how to display the information initially provided. In some embodiments, the determination includes which section to keep on the display and which section to hide upon a resizing of the display. In some embodiments, the determination is based at least in part on an analysis performed by the system. In some embodiments, the determination is based at least in part on an importance ranking. In some embodiments, the importance ranking is obtained through system analysis. In some embodiments, the importance ranking is created manually for one or more assets. In some embodiments, the importance ranking is based on one or more of: production flow impact, historical data, maintenance data, simulation data, AI training, or any other data source available to the system. In some embodiments, the importance ranking is different for different assets. In some embodiments, the importance ranking can cause different information to be hidden for a primary asset than is hidden for a secondary asset upon a display and/or window resizing. In some embodiments, a new set of information (e.g., one or more new headers, graphs, charts, time control, breadcrumbs, etc.) is displayed upon a resizing of a window and/or display.
In some embodiments one or more items on the display can be annotated and/or marked with a comment. In some embodiments, the alarm view page is divided into a plurality of windows or sections including one or more processes and/or alarms related to one or more industrial process systems. In some embodiments, one or more sections and/or columns can be hidden based one or more priorities as a displayed resolution reduces and width available for the visualization on the at least one user display is reduced. In some embodiments, a grouping of alarms of the alarm related information to be correlated to individual alarms based on one or more automatically assigned markers, the markers including a manual and/or system determined link. In some embodiments, AI is used to mark trends, as further discussed below.
In some embodiments, the alarm view page includes a header section, and/or breadcrumb section, and/or chart area section, and/or grid area section, and/or a time control section. Some embodiments further comprise program logic executed by the at least one processor that enables a display on the at least one user display of asset hierarchy within the breadcrumbs section. In some embodiments, each asset in the asset hierarchy is separated by a conventional character, graphic, token, and/or symbol.
Some embodiments further comprise program logic executed by the at least one processor that enables a user to interact with the at least one user display to show one or more asset children under a selected asset, where upon selecting a child asset, the breadcrumbs section is updated with a new asset hierarchy, and/or the chart area section is updated, and/or the grid area section is updated. Some embodiments further comprise a program logic (i.e., processor readable instructions) executed by the at least one processor that enables a further analysis of the alarm related information through single or multiple filters of groups of alarms to automatically provide a view of multiple alarms groups, and/or detailed alarm records of a set of one or more groups of alarms.
Some embodiments further comprise program logic executed by the at least one processor that enables a display on the at least one user display of one or more sections and/or columns of a grid with one or more sections and/or columns comprising one or more of a “time,” “severity,” “duration,” “condition,” “in alarm or not,” “sparkline,” “status,” “tag,” “object,” “area,” “value,” “limit,” and/or “unacknowledged.”
Some embodiments of the invention are related to training AI for production monitoring. In some embodiments, the system AI can be trained to recognize trend abnormalities. In some embodiments, the AI can be trained to project an event with a certain amount of certainty. In some embodiments, AI can be trained to recognize patterns in continuous trend data and label those patterns as steps. In some embodiments, AI can be trained to recognize visual defects using images and/or video feeds. In some embodiments, once an AI model is trained, the AI can raise alarms and feed relevant information to the system so that the most relevant alarm information is displayed.
In some embodiments, the historian 111 can include a time-series database 133 and a relational database 136. In at least one embodiment, the time-series database 133 and the relational database 136 can each derive data from various sources during data acquisition 130, including, but not limited to, one or more servers 131a, one or more human-machine-interface (HMI) applications 131b, at least one application server 131c, and/or manually entered and/or external data 131d. In some embodiments, time-series data can be provided in part by process control data stored in the time-series database 133, where the time-series data can be representative of historical plant or facility process information such as, for example, a continuum of process flow values measured over a period of time. In some embodiments, configuration data can, at least in part, be provided by the relational database 136, such as, configuration settings for a cloud service and associated storage capability utilized by the historian 111.
In some embodiments, the operational historian 202 can be adapted to store (e.g., “historize”) various types of data related to an industrial process. In some embodiments, the data includes, but is not limited to, time-series data, metadata, event data, configuration data, raw time-series binary data, tag metadata, diagnostic log data, and the like. In some embodiments, the operational historian 202 can be adapted to record trends and historical information about one or more industrial processes for future reference. For example, in some embodiments, the operational historian 202 can store data about various aspects of a facility process such as, but not limited to, an industrial process, in quantities that humans cannot interpret or analyze. For example, an operational historian may receive two million or more data values (e.g., tags relating to process control components, process variables, etc.) every second.
In some embodiments, the reporting service 204 can be adapted to retrieve data from operational historian 202, detect patterns in the retrieved data, generate reports that include information about the detected patterns, and store the generated reports in the report repository, such as a database 206. In some embodiments, reporting service 204 comprises processor-executable instructions embodied on a storage memory to provide reporting service 204 via a software environment and communications network. For example, in some embodiments, the reporting service 204 may be provided as processor-executable instructions that comprise a procedure, a function, a routine, a method, and/or a subprogram utilized independently or in conjunction with additional aspects of system 200 by computer 203 according to some embodiments of the disclosure. Further details of reporting service 204 are provided herein.
In some embodiments, the computer 203 can be adapted to provide the reporting service 204, report database 206 (or an interface to a computer-readable storage medium storing report database 206), curating service 208, user-specific report collection 210, general report collection 212, alert service 214, and search service 216, as further described herein. In some embodiments, the report database 206 can be adapted to store reports generated by reporting service 204 as an organized collection of data, as further described herein. In some embodiments, the user displays 218 can be adapted to receive from and transmit data to a user-specific report collection 210, and/or a general report collection 212, and/or an alert service 214, and/or search service 216, as further described herein. For example, in some embodiments, the reporting service 204 can be adapted to retrieve data from operational historian 202 by transmitting a query to operational historian 202, which operational historian 202 receives and uses to select stored data that matches the query. In some embodiments, the operational historian 202 can then transmit the selected data to reporting service 204. In some embodiments, the reporting service 204 can retrieve data continuously or at intervals. In some embodiments, the reporting service 204 can retrieve and/or receive data from additional sources, including reporting applications 206 (e.g., via an Application Programming Interface (API) of reporting service 204), built-in reporting services 208 (e.g., Wonderware® Online built-in reporters), application specific reporting services based on a client application configuration, and/or a “Human Machine Interface” (HMI), and/or any other conventional reporting service.
In some embodiments, the reporting service 204 can be adapted to analyze the data using algorithms and/or AI to detect certain patterns (e.g., “pattern of interest”) and/or non-conformities in the data for reporting and/or for triggering an alarm. For example, some algorithms include statistical algorithms, machine learning AI algorithms, rules-based algorithms, and the like, and upon the system detecting certain patterns, reporting service 204 can generate a report about these detected patterns according to some embodiments. In some embodiments, a report includes text, graphics (e.g., graphs, images, etc.), and/or metadata, and/or one or more alarms or alarm data. In some embodiments, the reports may include the information about the detected patterns in a format that is amenable to the curating service 208 and/or a format that is human-understandable when displayed via a display and/or an HMI. In some embodiments, a reporting service 204 can transform the data from a format that is unintelligible to curating service 208 and humans into a format that is intelligible to curating service 208 and humans when displayed via user devices (e.g., displays, screens, projectors, augmented reality glasses, headsets, and/or anything capable of presenting information visually) 218. Further, in some embodiments, after generating the reports, the reporting service 204 can transmit the reports to the report database 206 for storage.
In some embodiments, the report database 206 can be adapted to store reports as an organized collection of data. In some embodiments, report database 206 can store the reports in a central location for access by various systems and displays. In some embodiments, system 200 includes a plurality of reporting services 204 that are each able to retrieve data from operational historian 202, detect patterns in the data, generate reports, and store the reports in report database 206. In some embodiments that utilize a plurality of reporting services, each reporting service may operate independently or the collective operating services may operate in parallel on portions of a larger reporting task. In some embodiments, reports in database 206 can be available for accessing via the search service 216, and/or from a user-specific report collection 210, and/or general report collection 212, and/or a report can be transmitted in real-time in the form of an alert to one or more user displays 218 via an alert service 214. In some embodiments, the user displays 218 can be embodied as mobile displays with a mobile application (“app”). For example, aspects of the disclosure may be installed via app stores and aspects may be optimized for touchscreen according to some embodiments. In some embodiments, aspects of the disclosure may be browser-based, and can comprise data components including charts, trends, grids, etc.
In some embodiments, within the facility process system 300, the computer 203, operational historian 201, report database 206, user devices 218, and various components of the fluid processing system 310 (e.g., pump 303, valves 304, sensor 306, process controller 308) can be communicatively connected via the communication network 302. In some embodiments, the communication network 302 can facilitate the exchange of data among historian 201, computer 203, report database 206, one or more user devices 218, and components of fluid processing system 310.
In some embodiments, the communication network 302 in the embodiment of
In some embodiments, the fluid processing system 310 can be adapted for changing or refining raw materials to create end products (e.g., in the chemical, oil and gas, food and beverage, pharmaceutical, water treatment, and power industries). In some embodiments, the system is configured to optimize processes and processing systems other than fluid processing system 310. Example processes can include, but are not limited to, those in the chemical, oil and gas, food and beverage, pharmaceutical, water treatment, and power industries. In some embodiments, the process controller 308 can provide an interface or gateway between components of fluid processing system 310 (e.g., pump 303, valves 304, sensor 306) and other components of system 300 (e.g., historian 201, computer 203, report database 206, user devices 218). In some embodiments, components of fluid processing system 310 can communicate directly with the historian 201, and/or computer 203, and/or report database 206, and/or user devices 218 via communication network 302. In some embodiments, the process controller 308 can transmit data to and receives data from pump 303, and/or valves 304, and/or sensor 306 for controlling and/or monitoring various aspects of fluid processing system 310.
Some embodiments relate to improved processing and display of data in electronics including, for example, a computer and/or computer server (e.g., such as a computer system or server functioning as a manufacturing execution system) that provides a technological solution where users can efficiently monitor processes, retrieve, process, and view data. Some embodiments include a system and methods for arranging, structuring, and transmitting data or datasets in a computer or computer server using one or more data or data streams. In some embodiments, the data or datasets can comprise one or more alarms or alerts related to at least one asset.
Some embodiments include a computer-implemented method comprising program logic executed by at least one processor of a computer system that can provide an environment that allows users to utilize a graphical user interface (GUI) to visualize data or blocks of data, monitor data and alarms, including one or more transitions to or from an alarm or alert state (e.g., such as those that may be received from the industrial process system 300). For example, in some embodiments, the historian 111 may provide a tool for use by a user that enables the user to monitor storage blocks and functionality. Further, some embodiments enable a user to observe incoming event data, the merging of snapshots in a storage block, and responses to queries. In some embodiments, this information may be conveyed to a user in the form of text and/or graphics in the GUI. In some embodiments, the GUI may have a variety of icons indicating different event data, storage blocks, or snapshots, and alarms. Further, some embodiments include a computer-implemented method that includes: retrieving, by a computer system from a data store, a file comprising a plurality of data; displaying data or updating the display based at least in part on data or information related to the file via a display screen of a user interface in communication with the computer system.
Some embodiments include a system, server and computer-implemented program logic executed by at least one processor configured to represent hierarchical assets, along with various properties of each asset that can be uploaded to enable one or more users to search for higher level assets, rather than and/or addition to individual properties of assets, and then visualize at least one available alert and/or alarm for each matching asset.
In some embodiments, the system, server and method can include an audible alert or alarm correlated to a visual display, such as a display on one or more user devices 218. In some embodiments, the system can process a visualization that includes an automatic grouping of alarms of an asset, based on attributes of assets. In some embodiments, attributes of an asset can include monitored parameters of an asset such as time, temperature, pressure, power, flowrate, and/or any measurement that can be delivered visually or through an electrical signal. In some embodiments, the system can detect attributes such as visual changes and/or anomalies associated with a physical asset using a camera and/or any sensor that can detect propagated electromagnetic energy and convert that detection into an electrical signal. In some embodiments, the system can correlate the anomalies occurring in secondary assets to the conditions that caused an alarm in a primary asset. In some embodiments, the system predicts anomalies that will occur in secondary assets based on historical data including maintenance records, statistical analysis, continuous or intermittent correlation analysis, root cause analysis algorithms, AI training, and/or any other data source available.
In some embodiments, the system uses artificial intelligence, machine learning, and/or deep learning (collectively referred to herein as AI) to detect and/or sort through images and/or sensor data to perform analysis. In some embodiments, the system can analyze two or more assets in a process flow and generate reports, written or visual, that describe the effects that one asset's alarm condition can have on both upstream and downstream processes. In some embodiments the system can learn in real time if predicted effects match observed effects, and adjust predictions for both the present excursion and future events. In some embodiments, the system, server and method can provide rapid and readily understood visualization of alarms and reports on one or more displays. In some embodiments, the display can include a display of a computer system, a personal digital assistant, a cellular or smart phone, a digital tablet, and/or other fixed or mobile Internet appliances.
Some embodiments provide a computer-implemented system and method comprising program logic executed by at least one processor enabling a grouping of alarms, (e.g., such as one or more alarms of the aforementioned example embodiment of a facility process system 300), that can be correlated to individual alarms based on one or more automatically assigned markers. In some embodiments, the correlation between groups and individual alarm instances can be based on one to one and/or one to many mappings of attribute values for effective summarization of alarms, and/or unambiguous identification of one or more causes for individual alarm instances as well as the actions to take in response. In some embodiments, a further alarm analysis can be done through single or multiple filters of groups, which can automatically provide a view of multiple alarms groups, detailed alarm records, causes, and/or response actions of a set of one or more groups.
Some embodiments include a computer-implemented system and method comprising program logic executed by at least one processor enabling one or more users to visualize all related alarms for an asset based on one or more asset searches (e.g., such as one or more searches initiated through search service 216). Some embodiments can include an automatic grouping of alarms based on attributes of alarms and/or analysis done on those attributes. In some embodiments, the system can provide a cause and/or effect correlation between groups and individual alarm instances. In some embodiments, the system and method can automatically process (e.g., using AI) and display one or more intuitive groupings and corresponding details, and/or view a large number of alarms based on one or more assets, so that users can focus on the problem areas (such as which area of my plan has the most number of alarms yesterday) without needing to spend significant time to find the area with the most number of alarms.
In some embodiments, within the breadcrumbs section 420, the asset hierarchy is represented using breadcrumbs that can display directory paths of the current folder or webpage and provide access to each of the parent directories. In some embodiments, each asset in the asset hierarchy can be separated by a conventional graphic, token, symbol, and/or character (e.g., such as a special token “>” or any other suitable character or combination of characters and graphics). In some embodiments, by pressing the special token, a user can show one or more children under the selected asset. In some embodiments, by selecting a child asset, the system can refresh the breadcrumbs with the new asset hierarchy and/or update the chart area section 430, and/or grid area section 440. In some embodiments, the hierarchy leads to additional analysis that includes causes and/or action items. In some embodiments, the additional analysis is specific to the user.
In some embodiments, system can display one or more sections and/or columns of a grid (grid area section 440) with higher resolutions, including, but not limited to alarm information such as one or more of a, “time,” “severity,” “duration,” “condition,” “in alarm or not,” “sparkline,” “status,” “tag,” “object,” “area,” “value,” “limit,”, and/or “unacknowledged.” In some embodiments, as the resolution reduces (i.e., display size available for the grid is reduced), at least some of the columns can be hidden based one or more priorities specified by the user, the system, an administrator or other person or system. For example, in some embodiments, the system and method can process and display a shrinkage of the width and/or height of a “sparkline” as resolution reduces. In some embodiments, a “sparkline” is a conventional small line chart that displays the general shape of measurement variation. In some embodiments, the system can process and display one or more columns based on: time in alarm; the “unacknowledged” bar graph; an “object;” “area;” “limit;” and/or “value” column. In some embodiments, the system can process and display one or more columns based on text label for the alarm type (e.g. “High-High”), while the associated icon can remain. In some embodiments, a column comprises links to message boards, reports, causes, and/or action items previously saved in the system and/or provided by the system (e.g., through AI).
In some embodiments, the grid 510 can include an alarms column 550, including, but not limited to a data column 555, time column 558, and/or alert column 560 for displaying one or more different alert symbols. Further, in some embodiments, the grid 510 can include an “in alarm” column 562, condition column 564, alarm signal column 566, signal chart status column 568, tag column 570, and/or object column 572. Further, in some embodiments, the grid 510 can include an area column 574, value column 576, limit column 578, and/or unacknowledged column 580. In some other embodiments, the alarm view page 500 can be filtered by time or date using selection filter 590 shown at the bottom of the alarm view page 500.
In some embodiments, alarms can be grouped by alarm, tag, area and/or object according to a “Group By” control. In some embodiments, alarms can be selected based on condition using the selector 520, including, but not limited to, selected conditions 521, 523, 525, and 527. In reference to
In some embodiments, the grid can show color key rectangles next to data in all cells of the columns represented by the currently selected group (shown as alert column 560). In some embodiments, the Pareto chart 530 can then show a set of data representing the number of alarms grouped by current selection. In
Referring back to
Referring to
In some embodiments, item highlighting can occur when clicking columns or legend items of grid 510. In some embodiments, when the user first clicks on a column or legend item, that column and legend item can become highlighted, and all other columns or legend items can dim. In some embodiments, the user can click other columns or legend items that are dimmed to add them to the highlight. In some embodiments, when a highlight is in place, columns and legend items that are highlighted (i.e., not dimmed) can be clicked to remove items from the highlight. In some embodiments, once either all columns are highlighted, or all highlights are removed, the chart 530 can reenter the original state where no columns or legend items are dimmed.
In some embodiments, the Pareto chart 530 can be a fixed size when the screen height is tall, and once the screen is reduced in height below the initial height, the chart 530 can also shrink. In some embodiments, the legend area height can normally be a fixed height such that all legend items can display, and when the screen size is too small to show meaningful data in the column chart section, the legend area can shrink and include a scroll bar so the user can still access all legend items. In some embodiments, when the screen width reduces such that the time control overlaps the chart 530, the chart 530 container automatically resizes so that no overlap occurs. In some embodiments, a chart, such as the Pareto chart 530, is replace with a different chart upon resizing the screen or window.
In some embodiments, the system presents one or more of information, settings, and/or links on an explore page. In some embodiments, an explore page (or section) is a display that prioritizes information based on previously viewed and/or searched items. In some embodiments, using this time control, the system can quickly select predefined time selections and retrieve alarms records from the server based on past user interaction. In some embodiments, the start and end times can be customized in the explore page.
In some embodiments, the system and methods associated therewith can process data based on an asset hierarchy and selected time duration, where raw alarms are fetched from a system server such as computer 203. In some embodiments, during this phase, a grid area section can be displayed showing a basic skeleton, outline or template, (including some animation in some further embodiments) to indicate that the grid is waiting for data from the server, as well as to indicate conversion of raw data to grid format. In some embodiments, once the data is fetched from the server, the client can consolidate relevant records, and show the consolidated view in the grid.
In some embodiments, the system and method can process one or more rules that are applied during the alarm record consolidation. For example, in some embodiments, processed rules can group all records based on an alarm ID. In some embodiments, an end-time (‘et’) is calculated based on the current time (‘ct’) and an end time specified in the time control (‘tc.et’). In some embodiments, if ‘ct’ is greater than ‘tc.et,’ then ‘et’ will be ‘tc.et’ (i.e., the end time displayed to the user by the system is that which is specified in the time control). In some embodiments, if ‘ct’ is less than or equal to ‘et,’ then ‘et’ will be ‘ct’ (i.e., the end time is chosen as the current time by the system). In some embodiments, if end time ‘et’ is current time ‘ct’ then the display will continuously update with current time data as the current time changes.
In some embodiments, if the group contains an ‘alarm.set’ (alarm set) record, then an ‘unack’ (i.e., unacknowledged) duration is retrieved from ‘alarm_unackdurationms’ (alarm unacknowledged duration) property in the ‘alarm.aacknowledged’ (alarm acknowledged) record if it is present in the group. If not, then unack duration and/or an in-alarm duration are fetched from ‘alarm_durationms’ (alarm durations) in the ‘alarm.clear’ (alarm clear) record according to some embodiments. If both records (ack and clear) are not present, then unack duration and in-alarm duration are both calculated based on the end time ‘et’ as discussed above.
In some embodiments related to rule-based processing, if the group contains an ‘alarm.acknowledged’ record, then unacknowledged duration is retrieved from an ‘alarm_unackdurationms’ property in the ‘alarm.aacknowledged’ record. Later, “in-alarm” duration information is calculated based on the start time specified in the time control and event time registered in the ‘alarm.clear’ record if the ‘alarm.clear’ record is present. In some embodiments, if the ‘alarm.clear’ record is not present, then in alarm duration is calculated based on the start time specified in the time control and end time ‘et.’
In some embodiments, if the group contains only an ‘alarm.clear’ record, then unack duration and in alarm durations are calculated based on the start time specified in the time control and event time registered in the ‘alarm.clear’ record. Later, additional properties (such as “in-alarm”, “is-silenced”, and “is-shelved”) are calculated. For example, some embodiments include rule-based processing definitions that can comprise one or more of:
A. “In-Alarm”: Within the queried duration, this property is set to true for each alarm if the ‘Alarm.Clear’ record is not present for that alarm. If not, this property is set to false.
B. “Is-Shelved”: Within the queried duration, this property is retrieved from the last record of each alarm.
C. “Is-Silenced”: Within the queried duration, this property is retrieved from the last record of each alarm.
In some embodiments, spark lines (e.g., small inline or overlaid charts) are constructed by fetching process values from the system server for a specific tag mentioned in each alarm record. In some embodiments, if process values are empty for a given tag, then an empty spark line (which is indicated by filling spark line charts with a solid color in some embodiments) can be shown in the grid or grid section. In some embodiments, if the process values are present, then the spark line is drawn using process values. In some embodiments, after drawing the spark line, a section of the spark line is highlighted based on the ‘in alarm’ duration and colored according to the severity of the alarm.
In some embodiments, the system and method can process tests including, but not limited to: verify that the all the sections are present in the rendered page; verify predefined time selections can be selected in the time control; and/or verify custom time selection can be made in the time control.
In some embodiments, the operational historian interface 202 of
As a non-limiting example, an extrusion process model 3602 predicts with 80% certainty that a limit associated with tag (e.g., the tag listed in alarm summary 3607) will be violated in 52 minutes (as displayed in alarm details 3609). In some embodiments, the system displays that a cooling zone is stuck at 25° C. while pressure is increasing (in section 3610). In some embodiments, the system suggests increasing waterflow to the cooling zone to 4.5 gpm and continue to monitor to make sure the cooling zone temperature decreases to below 25° C.
In some embodiments, manufacturing facilities monitor remote equipment using one or more HMI (Human Machine Interfaces) displayed on one or more GUIs (Graphical User Interfaces). In some embodiments, remote monitoring is performed using SCADA (Supervisory Control and Data Acquisition) system. In some embodiments, SCADA system components include one or more of supervisory computers, remote terminal units, programmable logic controllers, communications infrastructure, and/or human-machine interfaces. In some embodiments, the SCADA system provides monitoring and command execution (e.g., changing setpoints, controlling scheduling, etc.). In some embodiments, the system uses conventional SCADA systems which are also referred to as RTUs (Remote Terminal Units). In some embodiments, the system is incorporated in SCADA systems provided by AVEVA®.
In some embodiments, facilities have various feeds that help monitor remote processes. In some embodiments, the feeds comprise digital information provided by conventional lens cameras, infrared cameras, digital cameras, visualization software (e.g., visualization software on an electron microscope that converts electronic signals and/or electromagnetic waves to a visual image) and/or video recording software and the like. As used herein, the term “camera” covers any of the aforementioned items and any conventional visualization hardware and/or software. As used herein, “alarm,” “alert,” “alarm/alert,” and/or “notification” includes any information that the system is capable of providing, such as, but not limited to, past trends, future predictions, historical data, maintenance data, root cause analysis, equipment mapping, links between alarms and secondary equipment, AI training interfaces, and/or any other method disclosed herein. In some embodiments, facilities have various manual visual inspections that need to be performed. In some embodiments, manual visual inspections components include gauges, lights, component movement, component color, size, shape, depth, vibration, and/or any other physical properties that can be classified as a visual characteristic. In some embodiments, the system uses conventional audio collectors (e.g., microphones) and the data collected therewith to monitor a process. In some embodiments, the system uses stress-strain gauges (e.g., wheatstone bridges). In some embodiments, the system uses images from the feed to transform one or more manual inspection station monitored components into a digital representation on the SCADA HMI. In some embodiments, the system helps to capture and analyze monitored data for integration into the SCADA system.
Similarly, in some embodiments, a camera visually monitoring gauges 3702 can send a digital representation to the system which then converts it to a digital value. The system is configured and arranged to convert the camera feed into digital representations continuously, intermittently, or upon changes in the gauges' 3702 positions, according to some embodiments. In some embodiments, the system is configured to compare a last received image with a current image, and only upload changes between the two images to a database, such as a historian database, for storage and/or analysis. In some embodiments, considerable memory capacity is saved by only storing changes in one or more process component images.
In some embodiments, remote components that require air vents 3703 are visually monitored using fan tells 3704 (e.g., paper that flaps, LEDs that light up, small veins that spin, and/or other conventional techniques) to ensure the fan is running and providing proper cooling. In some embodiments, components do not use fan tells and have sensors that send information to SCADA 3710. In some embodiments, the system is configured to receive a video feed from the camera and store the feed as a video clip. In some embodiments, the system uses a camera to take pictures at random time intervals of fan tell 3704. In some embodiments, the system is trained to interpret changes in the pictures to be an indication of a normal condition. In some embodiments, the system can be trained to interpret no change in the picture as an abnormal condition. In some embodiments, the system is trained to recognize motion in video clips and/or changes pictures as a normal condition. In some embodiments, the system uses this training to recognize an abnormal fan tell 3704 condition, such as when no movement of the vent tell 3704 is occurring. In some embodiments, the system reports the abnormal condition to the SCADA 3710 in the form of an alarm.
In some embodiments, the system uses a camera to monitor local electronic equipment such as oscilloscope 3705. In some embodiments, the remote electronic equipment such as oscilloscope 3705 does not send digital information to the SCADA 3710, and the system is used to transmit visual data for display and analysis. In some embodiments, the remote electronic equipment does send digital information to the SCADA 3710, and the system is used as redundancy to ensure what is displayed at the SCADA 3710 and what is displayed at the remote monitoring station 3700 are the same. In some embodiments, this redundancy can be applied to any electronic equipment that displays both a visual representation and/or reports signal data so that errors or loss of communication can be quickly detected and reported by the system as an alarm. In some embodiments, this feature is also desirable for gauges 3702 (and/or any analog device) that may have a display that is stuck and/or broken but is otherwise reporting correctly, in which case an alarm is reported by the system.
In some embodiments, the system monitors process hardware such as gears 3706, as a non-limiting example. In some embodiments, the system can monitor and record the movement of gears 3706 as a video clip and compares the current clip to a reference clip as described above. In some embodiments, the system monitors one or more components such as gears 3706 by taking pictures either intermittently or regularly. In some embodiments, videos and/or pictures can be compared to normal reference pictures stored during training and/or maintenance such that the system can determine if a physical component of the hardware is broken (e.g., a tooth is missing off of a gear). In some embodiments, the system can make predictions on how a defect in a physical component will affect the components operation, as well as the operation of any other component in the facility that is linked to the physical component's operation. In some embodiments, the system can use a change in a physical component to correlate to other unexpected anomalies in the process. For example, in some embodiments, the gears 3706 control the operation of levers 3707, 3708 when the remote station 3730 receives a signal from the SCADA 1110 according to some embodiments. In some embodiments, a broken tooth on a gear may result in a first lever 1107 raising as expected, but the lever 1107 only raising halfway. In some embodiments, the system monitoring both levers 3707, 3708 as well the gears 3706 correlates the lever abnormality to the gears abnormality and report the correlation with the alarm. In some embodiments, the system is capable of performing this type of correlation analysis using a combination of visual and electrically collected data.
In some embodiments, alarms are displayed on SCADA 3710. In some embodiments, SCADA 3710 includes one or more monitors 3711, televisions 3712, clients 3713, interfaces 3714 (e.g., keyboard, mouse, pad, etc.), computers 3715, and/or remote displays (not shown but described later). One or more SCADA components can be in a central location, distributed across the onsite facility, embodied in a mobile computer, and/or be located offsite while still remaining within the scope of this disclosure.
In some embodiments, as shown in
In some embodiments, the name 3904 serves to identify the AI profile that is created using the confirmation section 3903. In some embodiments, type 3905 defines the classification rule that the AI uses to assign each image. In some embodiments, such as shown in exemplary
In some embodiments, transfer model 3906 can be selected to import an AI model previously trained. In some embodiments, the imported AI model may have been used in similar analysis. In some embodiments, the imported AI model may have been used for the same analysis at a different location or facility. For example, in some embodiments, there are multiple pot shapes that are being produced at the same factory. In some embodiments, the defects found in the multiple pot shapes are similar, such as defect 3806, for example. In some embodiments, the system's AI can learn to recognize defects in one product from previous defect classifications in a different product. In some embodiments, importing an AI model using transfer model 3905 can significantly improve the AI training process by reducing the amount of manual feedback that is required at for a new model; manual training is discussed further below.
In some embodiments, model configuration 3903 involves setting an epoch threshold 3907. In some embodiments, an epoch defines the number of iterations that the learning algorithm (i.e., AI) will run through a training sample. In some embodiments, the system provides an input for dividing a sample size into a number of batches, where the model weights are updated after each batch. In some embodiments, batch types include batch gradient descent, stochastic gradient decent, and/or mini-batch gradient descent, as non-limiting examples. In some embodiments, and epoch threshold 3907 determines the number of epochs after which training will be stopped if there is no improvement in validation loss. In some embodiments, category 0 name 3908 and category 1 name 3909 are used to name each group created when type 3905 was selected (e.g., defective, not defective). In some embodiments, the model configuration is saved by selecting the save button 3913.
In some embodiments, to begin training the AI model the training checkbox 4011 is selected. In some embodiments, one or more images (e.g., 4008, 4009) are then manually chosen from the unclassified tab and classified (i.e, labeled defective or not defective) using one of the classification buttons 4012, 4013, 4015. In some embodiments, the classification buttons are an unclassified button 4012, an accepted button 4013, and/or a rejected button 4015. In some embodiments, once the one or more images are moved and/or copied from the unclassified tab 4005 to the accepted tab 4006 when the image is selected and the accepted button 4013 is chosen. In some embodiments, one or more images are moved and/or copied from the unclassified tab 4005 to the rejected tab 4007 when the image is selected and the accepted button 4014 is chosen. In some embodiments, the system uses manual classification to train the AI.
In some embodiments, the system uses one or more of a training set, a validation set, and/or a test set during training, tuning, model section, and/testing. In some embodiments, a majority of the images used for training are assigned to a training set. In some embodiments, the percentage of the images are assigned to a training set is between 40% and 80%. In some embodiments, the training sets are used to fit parameters for an adjusting weights process. In some embodiments, a minority of the images used for training are assigned to a validation set. In some embodiments, the percentage of the images are assigned to a validation set is between 10% and 30%. In some embodiments, the validation set is an intermediate phase in the AI training that is used for selecting the best model and/or optimizing the model. In some embodiments, a portion of the images used for training are assigned to a testing set. In some embodiments, the testing set comprises images that have been manually classified and is used for result testing and final model performance assessment.
In some embodiments the system uses a loss function to optimize the training process. In some embodiments, training sets and validation sets are used to calculate loss based on how well a model is performing using data from these two sets. In some embodiments, loss is the sum of the errors that occurred for each sample in the training sets or validation sets. In some embodiments, loss represents how desirable or undesirable a model behaves after each epoch iteration.
In some embodiments, the system uses an accuracy metric to interpret the AI model's performance. In some embodiments, accuracy represents the ratio of the number of correct predictions to the total number of predictions. In some embodiments, accuracy is used to gauge the model's prediction as compared to the true data.
In some embodiments, the system uses conventional algorithms and/or techniques for creating and/or testing an AI model. In some embodiments, the system uses proprietary algorithms and/or techniques for creating and/or testing an AI model.
In some embodiments, the same procedure for classifying defects as described above is also used to train the AI in any embodiment presented in this disclosure. In some embodiments, the same procedure for classifying defects as described above can be used to train the AI model for any application not disclosed herein.
Some embodiments may comprise a special purpose computer including a variety of computer hardware, as described in greater detail below. Some embodiments within the scope of the disclosure can also include computer-readable media for carrying or having computer-executable instructions or data structures stored thereon. In some embodiments, such computer-readable media can be any available media that can be accessed by a special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage, or other magnetic storage devices, or any other medium that can be used to carry or store desired program code means in the form of computer-executable instructions or data structures and that can be accessed by a general purpose or special purpose computer according to some embodiments. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computer, the computer properly views the connection as a computer-readable medium according to some embodiments. Thus, in some embodiments, any such connection is properly termed a computer-readable medium and/or processor-readable medium. In some embodiments, combinations of the above should also be included within the scope of computer-readable media. In some embodiments, computer-executable instructions comprise, for example, instructions and data which cause a general-purpose computer, special purpose computer, or special purpose processor to perform a certain function or group of functions.
Some embodiments include a system for implementing aspects of the disclosure that includes a special purpose computer in the form of a conventional computer, including a processing unit, a system memory, and a system bus that can couple various system components including the system memory to the processing unit. In some embodiments, the system bus may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. In some embodiments, the system memory includes read only memory (ROM) and random-access memory (RAM).
Further, some embodiments include a basic input/output system (BIOS), containing the basic routines that help transfer information between elements within the computer, such as during startup, may be stored in ROM. Further, in some embodiments, the computer may include any computer (e.g., processor, desktop computer, laptop, tablet, PDA, cell phone, mobile phone, smart television, and the like) capable of receiving or transmitting an IP address wirelessly to or from the Internet.
In some embodiments, the computer may also include a magnetic hard disk drive for reading from and writing to a magnetic hard disk, a magnetic disk drive for reading from or writing to a removable magnetic disk, and an optical disk drive for reading from or writing to removable optical disk such as a CD-ROM or other optical media. In some embodiments, the magnetic hard disk drive, magnetic disk drive, and optical disk drive can be connected to the system bus by a hard disk drive interface, a magnetic disk drive-interface, and an optical drive interface, respectively. In some embodiments, the drives and their associated computer-readable media can provide non-volatile storage of computer-executable instructions, data structures, program modules, and other data for the computer. Although the exemplary environment described herein employs a magnetic hard disk, a removable magnetic disk, and a removable optical disk, other types of computer readable media for storing data can be used, including, but not limited to, magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, RAMs, ROMs, solid state drives (SSDs), and the like according to some embodiments.
In some embodiments, the computer typically includes a variety of computer readable media. In some embodiments, computer readable media can be any available media that can be accessed by the computer and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, in some embodiments computer readable media may comprise computer storage media and communication media. Computer storage media include both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data according to some embodiments. In some embodiments, computer storage media are non-transitory and include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, SSDs, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired non-transitory information, which can be accessed by the computer. In some embodiments, communication media typically embody computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media.
Some embodiments include program modules comprising program code that may be stored on the hard disk, magnetic disk, optical disk, ROM, and/or RAM, including an operating system, one or more application programs, other program modules, and program data. In some embodiments, a user may enter commands and information into the computer through a keyboard, pointer, or other inputs such as a microphone, joy stick, game pad, satellite dish, scanner, or the like. In some embodiments, these and other inputs are often connected to the processing unit through a serial port interface coupled to the system bus. In some embodiments, the inputs may be connected by other interfaces, such as a parallel port, a game port, or a universal serial bus (USB). In some embodiments, the monitor or another display is also connected to the system bus via an interface, such as a video adapter. In addition to the monitor, in some embodiments, personal computers typically include other peripheral outputs (not shown), such as speakers and printers.
In some embodiments, one or more aspects of the disclosure may be embodied in computer-executable (computer-readable) instructions (i.e., software), routines, or functions stored in system memory or non-volatile memory as application programs, program modules, and/or program data. In some embodiments, the software may be stored remotely, such as on a remote computer with remote application programs. In some embodiments, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular data types when executed by a processor in a computer or other device. In some embodiments, the computer executable instructions may be stored on one or more tangible, non-transitory computer readable media (e.g., hard disk, optical disk, removable storage media, solid state memory, RAM, etc.) and executed by one or more processors or other devices, including any of the devices disclosed herein.
In some embodiments, the functionality of the program modules may be combined or distributed as desired. In some embodiments, the functionality may be embodied in whole or in part in firmware or hardware equivalents such as integrated circuits, application specific integrated circuits, field programmable gate arrays (FPGA), and the like. Further, in some embodiments, the computer may operate in a networked environment using logical connections to one or more remote computers. In some embodiments, the remote computers may each be another personal computer, a tablet, a PDA, a server, a router, a network PC, a peer device, or other common network node, and typically include many or all of the elements described above relative to the computer. In some embodiments, the logical connections include a local area network (LAN) and a wide area network (WAN) that are presented here by way of example and not limitation. In some embodiments, such networking environments are commonplace in office-wide or enterprise-wide computer networks, intranets and the Internet.
In some embodiments, when used in a LAN networking environment, the computer can be connected to the local network through a network interface or adapter. When used in a WAN networking environment, the computer may include a modem, a wireless link, or other means for establishing communications over the wide area network, such as the Internet according to some embodiments. In some embodiments, the modem, which may be internal or external, is connected to the system bus via the serial port interface. In some embodiments, in a network environment program modules depicted relative to the computer, or portions thereof, may be stored in the remote memory storage. It will be appreciated that the network connections shown are exemplary and other means of establishing communications over wide area network may be used in some embodiments.
In some embodiments, the computer-executable instructions are stored in a memory, such as the hard disk drive, and executed by the computer. Advantageously, in some embodiments, the computer processor has the capability to perform all operations (e.g., execute computer-executable instructions) in real-time. In some embodiments, the order of execution or performance of the operations in embodiments of the disclosure illustrated and described herein is not essential, unless otherwise specified. That is, in some embodiments, the operations may be performed in any order, unless otherwise specified, and embodiments of the disclosure may include additional or fewer operations than those disclosed herein. For example, in some embodiments, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the disclosure.
Some embodiments of the disclosure may be implemented with computer-executable (i.e., processor-executable, processor-readable) instructions. In some embodiments, the computer-executable instructions may be organized into one or more computer-executable components or modules. In some embodiments, aspects of the disclosure may be implemented with any number and organization of such components or modules. For example, in some embodiments, aspects of the disclosure are not limited to the specific computer-executable instructions or the specific components or modules illustrated in the figures and described herein. Some embodiments of the disclosure may include different computer-executable instructions or components having more or less functionality than illustrated and described herein.
For the purposes of this disclosure in some embodiments the term “server” should be understood to refer to a service point which provides processing, database, and communication facilities in some embodiments. In some embodiments, a computer may be capable of sending or receiving signals, such as via a wired or wireless network, or may be capable of processing or storing signals, such as in memory as physical memory states, and may, therefore, operate as a server. Thus, in some embodiments, devices capable of operating as a server may include, as examples, dedicated rack-mounted servers, desktop computers, laptop computers, set top boxes, integrated devices combining various features, such as two or more features of the foregoing devices, or the like. By way of example, and not limitation, in some embodiments, the term “server” can refer to a single, physical processor with associated communications and data storage and database facilities, or it can refer to a networked or clustered complex of processors and associated network and storage, as well as operating software and one or more database systems and application software that support the services provided by the server. In some embodiments, servers may vary widely in configuration or capabilities, but generally a server may include one or more central processing units and memory according to some embodiments. In some embodiments, a server may also include one or more mass storage, one or more power supplies, one or more wired or wireless network interfaces, one or more input/output interfaces, or one or more operating systems, such as a Microsoft® Windows® Server, Mac OS X, Unix, Linux, and/or any other conventional operating system. Microsoft® and Windows® are registered trademarks of Microsoft Corporation, Redmond, Wash.
For the purposes of this disclosure a “network” should be understood to refer to a network that may couple devices so that communications may be exchanged, such as between a server and a client, peer to peer communications, or other types of devices, including between wireless devices coupled via a wireless network, for example in some embodiments. In some embodiments, a network may also include mass storage, such as network attached storage (NAS), a storage area network (SAN), or other forms of computer or machine-readable media, for example. In some embodiments, a network may include the Internet, one or more local area networks (LANs), one or more wide area networks (WANs), wire-line type connections, wireless type connections, cellular or any combination thereof. Likewise, in some embodiments, sub-networks, which may employ differing architectures or may be compliant or compatible with differing protocols, may interoperate within a larger network. In some embodiments, various types of devices may, for example, be made available to provide an interoperable capability for differing architectures or protocols. In some embodiments, a router may provide a link between otherwise separate and independent LANs. In some embodiments, a communication link or channel may include, for example, analog telephone lines, such as a twisted wire pair, a coaxial cable, full or fractional digital lines including T1, T2, T3, or T4 type lines, “Integrated Services Digital Networks” (ISDNs), “Digital Subscriber Lines” (DSLs), wireless links including satellite links, or other communication links or channels, such as may be known to those skilled in the art. Furthermore, in some embodiments, a computer or other types of related electronics may be remotely coupled to a network, such as via a telephone line, cell line, and/or satellite link, for example.
For purposes of this disclosure, in some embodiments, a “wireless network” should be understood to couple a user and/or client with a network. A wireless network may employ stand-alone ad-hoc networks, mesh networks, wireless LAN (WLAN) networks, cellular networks, or the like according to some embodiments. In some embodiments, a wireless network may further include a system of terminals, gateways, routers, or the like coupled by wireless radio links, or the like, which may move freely, randomly or organize themselves arbitrarily, such that network topology may change, at times rapidly. In some embodiments, a wireless network may further employ a plurality of network access technologies, including “Long Term Evolution” (LTE), WLAN, wireless router (WR) mesh, or 2nd, 3rd, 4th, or 5th generation (2G, 3G, 4G, or 5G) cellular technology, or the like. In some embodiments, network access technologies may enable wide area coverage for devices, such as clients with varying degrees of mobility. For example, in some embodiments, a network may enable RF or wireless type communication via one or more network access technologies, such as “Global System for Mobile communication” (GSM), “Universal Mobile Telecommunications System” (UMTS), “General Packet Radio Services” (GPRS), “Enhanced Data GSM Environment” (EDGE), 3GPP LTE, LTE Advanced, “Wideband Code Division Multiple Access” (WCDMA), Bluetooth®, 802.11b/g/n, or the like. In some embodiments, a wireless network may include virtually any type of wireless communication mechanism by which signals may be communicated between devices, such as a client (i.e., a computer accessing a server) and/or a computer, between and/or within a network, or the like.
For purposes of this disclosure, in some embodiments, a client (or consumer or user) may include a computer capable of sending or receiving signals, such as via a wired or a wireless network. In some embodiments, a client may, for example, include a desktop computer or a portable device, such as a cellular telephone, a smart phone, a display pager, a radio frequency (RF) transmitter/receiver, an infrared (IR) transmitter/receiver, a near field communication (NFC) transmitter/receiver, a personal digital assistant (PDA), a handheld computer, a tablet computer, a phablet, a laptop computer, a set top box, a wearable computer, an integrated device combining various features, such as features of the forgoing devices, or the like.
In some embodiments, a client device may vary in terms of capabilities or features, and claimed subject matter is intended to cover a wide range of potential variations. In some embodiments, a web-enabled fixed or mobile device may include a browser application that is configured to receive and to send web pages, web-based messages, and the like. The browser application may be configured to receive and display graphics, text, multimedia, and the like, employing virtually any conventional web-based language according to some embodiments.
It is to be understood that the system is not limited in its application to the details of construction and the arrangement of components set forth in the previous description or illustrated in the drawings according to some embodiments. The system is capable of combining elements from some embodiments and of being practiced or of being carried out in various ways. Also, in some embodiments, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items according to some embodiments. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings according to some embodiments. Further, in some embodiments, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. In some embodiments, the term “substantially” as used herein includes a range of ±10% of the unit of measure associated therewith unless otherwise indicated.
In some embodiments, the previous discussion is presented to enable a person skilled in the art to make and use the embodiments disclosed herein. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the principles of one or more embodiments can be applied to other embodiments and applications without departing from the scope of the disclosure according to some embodiments. Thus, some embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. In some embodiments, the previous detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict some embodiments and are not intended to limit the scope of any embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of the disclosure according to some embodiments.
Some embodiments disclosed herein generally describe non-conventional approaches for systems and methods for process data management and visualization of data alarms that are not well-known, and further, are not taught or suggested by any known conventional methods or systems. Moreover, in some embodiments, the specific functional features are a significant technological improvement over conventional methods and systems, including at least the operation and functioning of a computing system that are technological improvements. In some embodiments, these technological improvements include one or more aspects of the system and methods described herein that describe the specifics of how a machine operates, and improvements to the machine operation with respect to the prior art, which the Federal Circuit makes clear is the essence of statutory subject matter.
In some embodiments, one or more of the embodiments described herein include functional limitations that cooperate in an ordered combination to transform the operation of a data repository in a way that improves the problem of data storage and updating of databases that previously existed. Some embodiments described herein include a system and methods for managing single or multiple content data items across disparate sources or applications that create a problem for users of such systems and services, and where maintaining reliable control over distributed information is difficult or impossible.
The description herein further describes some embodiments that provide novel features that improve the performance of communication and software, systems and servers by providing automated functionality that effectively and more efficiently manages resources and asset data for a user in a way that cannot effectively be done manually. Therefore, the person of ordinary skill can easily recognize that these functions provide the automated functionality, as described herein, in a manner that is not well-known, and certainly not conventional. As such, of the system described herein is not directed to an abstract idea and provides a significant tangible innovation. Moreover, the functionalities described herein were not imaginable in previously-existing computing systems, and did not exist until the disclosed system solved the technical problem described earlier.
In some embodiments, it is recognized in the disclosure herein that enabling a user to visualize all related alarms for or related to an asset based on one or more asset searches, coordinating an automatic grouping of alarms, and/or a correlation between groups and individual alarm instances causes a new computing function, and is a technical problem for network communication and other server based technologies according to some embodiments. Some embodiments herein provide one or more technological solutions in the realm computer implementations of one or more graphical displays of grouped and correlated data with analysis of alarms in real-time with communications across a network, computers, databases, and/or the Internet to improve the performance of, and technology of representing hierarchical assets and properties of those assets in ways that cannot effectively be done, or done at all, manually.
It will be appreciated by those skilled in the art that while the system has been described above in connection with some embodiments and examples, the system is not necessarily so limited, and that numerous embodiments, examples, uses, modifications and departures from some embodiments, examples and uses are intended to be encompassed by the description, figures, and claims attached hereto.
Having described aspects of the disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the disclosure as defined in the appended claims according to some embodiments. In some embodiments, as various changes could be made in the above constructions, products, and methods without departing from the scope of aspects of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
Claims
1. A system for improving emergency information delivery comprising:
- at least one processor,
- at least one non-transitory processor readable medium with instructions stored thereon configured and arranged to: read asset data from a database; compare the asset data to one or more alarm limits; display alarm information when a primary asset's parameter exceeds the one or more alarm limits; and determine secondary information to display in conjunction with the alarm.
2. The system of claim 1,
- wherein the system selects the secondary information to display based on one or more attributes of the primary asset.
3. The system of claim 1,
- wherein the system selects the secondary information to display based on one or more attributes of one or more secondary assets.
4. The system of claim 1,
- wherein the system selects at least part of the secondary information to display based on one or more links between one or more attributes of the primary asset and one or more attributes of a secondary asset; and
- wherein one or more links comprise at least one of correlation analysis and/or a manual link.
5. The system of claim 1,
- wherein the system is configured and arranged to provide a root cause analysis based on historical data; and
- wherein the root cause analysis is as at least part of the secondary information.
6. The system of claim 4,
- wherein the system is configured and arranged to identify anomalies in one or more secondary assets and display the anomalies as at least part of the secondary information.
7. The system of claim 4,
- wherein determining secondary information to display in conjunction with the alarm comprises creating separate groups;
- wherein each separate group comprises at least a different portion of the secondary information; and
- wherein the system is configured and arranged to allow a user to select each one of the separate groups to display the secondary information associated therewith.
8. A system for improving emergency information delivery comprising:
- at least one processor,
- at least one non-transitory processor readable medium with instructions stored thereon configured and arranged to: read asset data from a database; compare the asset data to one or more alarm limits; generate an alarm when a primary asset's parameter exceeds the one or more alarm limits; determine information to display in conjunction with the alarm; and generate a display comprising a visual representation of the alarm and the information.
9. The system of claim 8,
- wherein the display comprises a header, breadcrumbs, a chart area, a grid area, and a time control.
10. The system of claim 9,
- wherein the breadcrumbs comprise an asset hierarchy;
- wherein each asset in the asset hierarchy is separated by a special token;
- wherein pressing the special token will show a list of one or more child assets;
- wherein selecting a child asset will refresh the breadcrumbs to include the child asset's hierarchy;
- wherein selecting a child asset will update the header, chart area, grid area, and time control with child asset information.
11. The system of claim 8,
- wherein information comprises primary information about a primary asset; and
- wherein information comprises secondary information about a secondary asset.
12. The system of claim 11,
- wherein secondary information comprises at least one secondary asset alarm.
13. The system of claim 11,
- wherein the determining information to display comprises the system using an attribute map with one or more links that link the primary asset to the secondary asset.
14. The system of claim 13,
- wherein the one or more links comprise at least one of correlation analysis and/or a manual link.
15. A system for improving emergency information delivery comprising:
- at least one processor,
- at least one non-transitory processor readable medium with instructions stored thereon configured and arranged to: read asset data from a database; compare the asset data to one or more alarm limits; generate an alarm when a primary asset's parameter exceeds the one or more alarm limits; determine asset data information to display in a plurality of sections; determine an importance ranking for each of the plurality of sections; generate a display comprising a visual representation of the alarm and the plurality of sections; and determine which section to keep on the display and which section to hide upon a resizing of the display.
16. The system of claim 15,
- wherein the determining the importance ranking for each of the plurality of sections is based at least in part on analysis performed by the system; and
- wherein the importance ranking and the analysis can differ for different asset alarms.
17. The system of claim 15,
- wherein the determining which section to keep on the display and which section to hide upon a resizing of the display is based at least in part on an analysis performed by the system; and
- wherein the determining which section to keep on the display and which section to hide upon a resizing of the display can differ for different asset alarms.
18. The system of claim 15,
- wherein the determining which section to keep on the display and which section to hide upon a resizing of the display comprising the system displaying at least one of a new graph and/or chart representing at least a portion of the asset data information in the kept section.
19. The system of claim 15,
- wherein the determining which section to keep on the display and which section to hide upon a resizing of the display comprising the system displaying at least one of a new graph and/or chart representing at least a portion of the asset data information in the hidden section.
20. The system of claim 15,
- wherein the determining which section to keep on the display and which section to hide upon a resizing of the display is based on one or more links between one or more attributes of the primary asset and one or more attributes of a secondary asset; and
- wherein one or more links comprise at least one of correlation analysis and/or a manual link.
Type: Application
Filed: Feb 14, 2020
Publication Date: Oct 15, 2020
Inventors: Ravi Kumar Herunde Prakash (Lake Forest, CA), Sudhir Gonugunta (Rancho Santa Margarita, CA), Vinay Kamath (Rancho Santa Margarita, CA), Sripraneeth Nara (Lake Forest, CA)
Application Number: 16/791,423
