A system includes a computer numerical control (CNC) machining system configured to perform a machining operation to define a feature on a workpiece and a machine edge controller disposed external of the machining system and in communication with the CNC machine system. The machine edge controller is configured to perform a machining evaluation during the machining operation. In executing the machining evaluation, the machine edge controller is configured to acquire data indicative of characteristics of the CNC machining system during the machining operation and compare the data with one or more machining baseline parameters associated with the machining operation to determine an abnormal operation of the CNC machining system. The one or more machining baseline parameters define a nominal response of the CNC machining system for performing the machining operation.

In one embodiment, a system may include a multi-purpose sensor coupled to a machine operating in an industrial environment. The multi-purpose sensor may include a camera that obtains a first and second set of image data including images of the machine and an environment surrounding the machine. The first set of image data is associated with a baseline of the machine and the environment, and the second set of image data is acquired subsequent to when the first set is acquired. The system may include a computing device that may include a processor to receive the first and second set of image data, determine baseline positions of objects in the first set, determine subsequent positions of the objects in the second set, determine whether the subsequent positions vary from the baseline positions, and perform an action when the subsequent positions vary from the baseline positions.

A safety input device for use in a single-wire safety system comprises a fast-switching architecture that allows a safety signal to propagate through the safety device to downstream devices with negligible delay. Rather than placing the signal processor in-line between the signal input and output terminals of the safety device, an electronic switch is placed between the input and output terminals. A signal processor in parallel with the switch monitors the incoming signal and closes the switch if the safety signal is absent, effectively shorting the input and output terminals and allowing the incoming safety signal to pass substantially instantaneously. Loss of the safety signal at the input terminal is immediately reflected by the loss of safety signal output at the output terminal, eliminating processing delay between loss of the safety signal at the input terminal and cessation of the output signal at the output terminal.

A method for automatic monitoring of industrial control systems, comprising: monitoring an environment by an electromagnetic sensor to measure a plurality of electromagnetic pulses emitted by at least one industrial control device during operation of the at least one industrial control device; calculating automatically at least one normal data pattern based on an analysis of the plurality of electromagnetic pulses; matching between at least one new electromagnetic pulse measured by the electromagnetic sensor and the at least one normal data pattern to automatically detect at least one abnormal data pattern; and sending automatically a security alert in response to the abnormal data pattern.

A system for analyzing operational data associated with a plant that has processing equipment configured and controlled to run a process involving at least one tangible material. Actual operational data corresponding to plant operations is received by a computing device that may relate to production, equipment, workforce, automation systems, safety, and/or cybersecurity of the plant. A model of the plant is generated based on the actual operational data, where the model indicates ideal plant operations including model operational data. The actual plant operational data and the model operational data are compared. Based on the operational data and the comparison of the operational data to model operational data, at least one recommendation for an action associated with the plant is determined.

A computing system for receiving operational data including process parameters generated by sensors in a plant. An analysis engine uses the operational data to automatically provide a first listing of worst performing process parameters, that when a selected poor performing process parameter is chosen generates a ranked filtered view of equipment parameters for associated processing equipment that may be affected by the selected poor performing parameter and a filtered view of recommendations for recognizing action(s) to fix the associated processing equipment and/or the selected poor performing process parameter, and/or a second listing of worst performing processing equipment that when a selected poor performing processing equipment is chosen generates a ranked filtered view of suspected process parameters that may be affected by the selected poor performing processing equipment along with a filtered view of recommendations for recognizing action(s) to fix the selected poor performing processing equipment and the suspected process parameters.

Monitored control system includes an action device and a monitoring device for monitoring the operation of the action device. The action device includes actuator modules, a sensor module and a control module to command the actuator modules to perform a predefined task using the sensor data. The monitoring device receive monitored data from the action device and compute an action device operation indicator indicative of a correct or abnormal operation of the action device on the basis of the monitored data. The action device operation indicator is computed on the basis of a learned value of an adjustable monitoring parameter. The learned value is determined from a set of labelled data generated from trial datasets recorded by the action device during an iterative learning procedure.

An apparatus for configuring validation, estimation, and editing (VEE) rules for performing VEE on interval-based energy consumption streams includes a data stores, a rules processor, and a process control element. The stores provides tagged data sets each associated with a corresponding one of the streams, each of the sets comprising groups of contiguous interval values tagged as having been validated. The rules processor reads the stores upon initiation of an event and, for the each of the sets, creates anomalies having different durations using only the groups of values, the groups of values corresponding to correct data, and generates estimates for the anomalies by employing estimation techniques for each of the durations and, for the each of the durations, selects a corresponding one of the techniques for subsequent employment when performing VEE of subsequent energy consumption data associated with the each of the durations for the corresponding one of the streams. The control element executes functions on the streams translated by the rules processor, and directs one or more system elements to change state.

A system includes a computer numerical control (CNC) machining system configured to perform a machining operation to define a feature on a workpiece and a machine edge controller disposed external of the machining system and in communication with the CNC machine system. The machine edge controller is configured to perform a machining evaluation during the machining operation. In executing the machining evaluation, the machine edge controller is configured to acquire data indicative of characteristics of the CNC machining system during the machining operation and compare the data with one or more machining baseline parameters associated with the machining operation to determine an abnormal operation of the CNC machining system. The one or more machining baseline parameters define a nominal response of the CNC machining system for performing the machining operation.

A method for automatic monitoring of industrial control systems, comprising: monitoring an environment by an electromagnetic sensor to measure a plurality of electromagnetic pulses emitted by at least one industrial control device during operation of the at least one industrial control device; calculating automatically at least one normal data pattern based on an analysis of the plurality of electromagnetic pulses; matching between at least one new electromagnetic pulse measured by the electromagnetic sensor and the at least one normal data pattern to automatically detect at least one abnormal data pattern; and sending automatically a security alert in response to the abnormal data pattern.