CUSTOMIZABLE DATA PROCESSING AND NOTIFICATION SYSTEM FOR EQUIPMENT SENSOR MONITORING AND ALERT NOTIFICATIONS
20210166168 · 2021-06-03
Inventors
- Ivan Pedreros (Kansas City, KS, US)
- Connie McCabe (Kansas City, MO, US)
- Carlos Eduardo Alvarado Pedreros (Kansas City, MO, US)
Cpc classification
Y02P90/84
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
A system for receiving and processing data in real time on the cloud to trigger notifications and work procedures. The data received is based on pattern matching and anomaly detection streamed by sensors distributed in different networks and/or geographic locations. This system allows users to simplify the analysis, identification of and response to patterns in data that may indicate the near occurrence of an event that could negatively affect the user's assets, machinery, equipment and/or people. With this system, such damaging incidents may be prevented or minimized by taking early action via immediate communication mechanisms with key users and execution of tasks by autonomous equipment and personnel in the field.
Claims
1. A data processing and notification system comprising: an asset comprising a sensor, said sensor comprising at least one sensor key, said at least one sensor key configured to electronically identify and communication an identity of said sensor; a computer database comprising a graphical user interface (GUI), computer processing unit (CPU), and data storage; a communications network connecting said asset with said computer database; a data normalization and correlation engine operable by said CPU; a pattern matching, classification, and anomaly detection engine operable by said CPU; a notifications and work procedures engine operable by said CPU; a plurality of notification channels stored within said data storage and accessible by said CPU, said plurality of notification channels associated with a plurality of users; said sensor configured to generate a notification, said notification configured to be analyzed through said data normalization and correlation engine, said pattern matching, classification, and anomaly detection engine, and said notifications and work procedures engine by said CPU, thereby generating a determination; and said determination configured to trigger an action, said action communicated to said asset and said action performed by said asset.
2. The data processing and notification system of claim 1, further comprising: said asset comprising a plurality of peripheral devices; and said action configured to control at least one of said plurality of said peripheral devices.
3. A method of detecting errors in a network of assets, reporting, and correcting the errors, the method comprising the steps: monitoring an asset with a sensor, said asset in wireless communication with a wireless network; sending reporting data through said wireless network from said sensor to a data endpoint on a predetermined schedule, said data endpoint communicatively connected with a remote server comprising a data storage unit, central processing unit (CPU), and network connection, and said reporting data comprising a sensor key; assessing and validating said reporting data with said remote server; confirming said sensor key with said remote server; reviewing said reporting data with a data normalization and correlation engine; preparing said reporting data for a pattern matching, classification, and anomaly-detection engine with said data normalization and correlation engine by transforming said reporting data into raw data; checking for and removing duplicated data of said raw data with said data normalization and correlation engine; correlating said normalized data according to correlation rules stored within said data storage unit, thereby generating correlated data; sending said raw data and said correlated data to said pattern matching, classification, and anomaly-detection engine; checking for and applying pattern-match rules to the raw data and the correlated data with said pattern matching, classification, and anomaly-detection engine; checking for and applying classifiers to the raw data and the correlated data said pattern matching, classification, and anomaly-detection engine; checking for and applying anomaly detection models to the raw data and the correlated data said pattern matching, classification, and anomaly-detection engine; generating and sending a notice message to a notifications and work procedures engine with the pattern matching, classification, and anomaly-detection engine, said message containing response protocols to said raw data and said correlated data as analyzed via the pattern matching, classification, and anomaly-detection engine; generating and sending an instructional message to personnel, said instructional message comprising instructional response commands regarding based upon raw data and said correlated data as analyzed via the pattern matching, classification, and anomaly-detection engine; automatically adjusting performance protocols of said asset based upon said notice message; and wherein said data normalization and correlation engine, said pattern matching, classification, and anomaly-detection engine, and said notifications and work procedures engine are procedural computerized processes run by said central server CPU.
4. The method of claim 3, further comprising the step of sorting said raw data.
5. The method of claim 3, further comprising the step: activating said notifications and work procedures engine upon detection of a pattern-match with said pattern-match rules within said pattern matching, classification, and anomaly-detection engine.
6. The method of claim 3, further comprising the steps: running a data classifier model upon detection of classifiers within said pattern matching, classification, and anomaly-detection engine; recognizing a pattern match exists with said pattern matching, classification, and anomaly-detection engine; and activating said notifications and work procedures engine upon detection of a pattern-match with said pattern-match rules within said pattern matching, classification, and anomaly-detection engine.
7. The method of claim 3, further comprising the steps: running an anomaly detection model upon detection of an anomaly within said pattern matching, classification, and anomaly-detection engine; recognizing a pattern match exists with said pattern matching, classification, and anomaly-detection engine; and activating said notifications and work procedures engine upon detection of a pattern-match with said pattern-match rules within said pattern matching, classification, and anomaly-detection engine.
8. The method of claim 3, wherein said sensor key comprises a digital alphanumeric key configured to establish a connection with said wireless network.
9. The method of claim 3, wherein said sensor key comprises a digital alphanumeric key configured to identify said sensor as a unique logic unit.
10. A method of monitoring a machine asset, the method comprising the steps: performing a physical function with the machine asset; monitoring said physical function of the machine asset with a sensor, said sensor in wireless communication with a wireless network; sending reporting data through said wireless network from said sensor to a data endpoint on a predetermined schedule, said data endpoint communicatively connected with a remote server comprising a data storage unit, central processing unit (CPU), and network connection, and said reporting data comprising a sensor key; said reporting data comprising data related to said physical function of said machine asset; assessing and validating said reporting data with said remote server; confirming said sensor key with said remote server; reviewing said reporting data with a data normalization and correlation engine; preparing said reporting data for a pattern matching, classification, and anomaly-detection engine with said data normalization and correlation engine by transforming said reporting data into raw data; checking for and removing duplicated data of said raw data with said data normalization and correlation engine; correlating said normalized data according to correlation rules stored within said data storage unit, thereby generating correlated data; sending said raw data and said correlated data to said pattern matching, classification, and anomaly-detection engine; checking for and applying pattern-match rules to the raw data and the correlated data with said pattern matching, classification, and anomaly-detection engine; checking for and applying classifiers to the raw data and the correlated data said pattern matching, classification, and anomaly-detection engine; checking for and applying anomaly detection models to the raw data and the correlated data said pattern matching, classification, and anomaly-detection engine; generating and sending a notice message to a notifications and work procedures engine with the pattern matching, classification, and anomaly-detection engine, said message containing response protocols to said raw data and said correlated data as analyzed via the pattern matching, classification, and anomaly-detection engine; generating and sending an instructional message to personnel, said instructional message comprising instructional response commands regarding based upon raw data and said correlated data as analyzed via the pattern matching, classification, and anomaly-detection engine; automatically adjusting performance protocols of said asset based upon said notice message; and wherein said data normalization and correlation engine, said pattern matching, classification, and anomaly-detection engine, and said notifications and work procedures engine are procedural computerized processes run by said central server CPU.
11. The method of claim 10, wherein: said machine asset comprises a vehicle; and said physical function comprises movement of an element of said vehicle.
12. The method of claim 10, wherein: said machine asset comprises a machine having internal components; and said physical function comprises activities undertaken by at least one of said internal components.
13. The method of claim 10, wherein: said sensor comprises an external sensor configured to monitor environmental elements external to said machine asset; and said physical function comprises functions of said machine asset affected by said environmental elements.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
[0014] As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.
[0015] Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
II. Preferred Embodiment Data Processing and Notification System 2
[0016] As shown in
[0017] Mathematical formulae which may be implemented in interpreting sensor 8 data from assets 6 would include arithmetic operations over one or more data fields; threshold validation such as determining field values over, under, or between certain predetermined value levels; power, square root, or other linear or polynomial calculations on one or more data fields; count or aggregation of data fields, such as reading and reporting the number of data packages that comply with one or more logic rules; or other mathematical formulas as specified by users or personnel which may be asset-dependent for maximizing performance while minimizing risk to the assets.
[0018] Models which may be implemented in determining asset 6 operation based upon received sensor 8 data would include linear or polynomial interpolation models; statistical models based on past data related to the specific asset(s) 6; environmental models, which may include predictive weather or other environmental factors as detailed more below; and other models designed for specific industry and/or case-specific analysis as needed.
[0019] Algorithms which may be used in conjunction with the formulae and models above would include algorithms composed of one or more mathematical formulas and/or models as indicated above; alphanumeric and regular expression processing algorithms; geographical and spatial matching and analysis algorithms; and other algorithms designed for specific industry and/or case-specific analysis as needed.
[0020] Pattern matching logic and mathematical models could include the same mathematical, models, and algorithms as indicated above, as well as neural networks for anomaly detection; neural networks for sentiment analysis in alphanumeric information; neural networks for text classification in alphanumeric information; neural networks for classification over one or more data fields; ensemble neural networks which weight their results to provide an output; and other machine learning models designed for specific industry and/or case-specific analysis as needed.
[0021] External sensor devices 8, such as environmental monitoring stations which monitor weather, CO2, water streams, or other environmental elements that may affect or relate to a job site, or any other of independent sensor that may be performing measurements and/or actions without being part of a physical asset 6 such as a truck, robot or other physical machinery, may also be necessary for receiving and determining necessary steps in practicing the present invention. For example, if weather monitoring stations indicate impactful weather forecasts that may make it difficult for a specific asset 6 to perform its function without taking additional steps, messaging to the appropriate personnel may be necessary. Alternatively, the system could automatically direct these assets 6 to automatically perform steps which will protect their functions, such as limiting speed, increasing heating peripherals, or other important optional functions.
[0022] When this Pattern Matching, Classification & Anomaly Detection Engine 14 detects a pattern, specific class/group of classes or an anomaly, it sends a signal to the Notifications & Work Procedures Engine 18, again comprising the same or a different CPU, which starts a notification graph comprised of nodes that represent actions generally described as Notification Channels 22, such as sending an instant message through different communications channels to one or more users or calling one or more users via phone to give a prerecorded message or one generated by a computer-based user configuration and contextual data provided by the Notifications & Work Procedures Engine 18.
[0023] This mechanism can also communicate with an external application through an internet protocol and send parameters based on user configurations or contextual information provided by the Notifications & Work Procedures Engine 18, and/or enqueue a command to a Remote Commands Engine 20 with additional parameters provided by the Notifications & Work Procedures Engine 18. These commands are transmitted to one or more Sensor Devices 8 and once received are used by said sensors 8 to execute specific tasks such as (but not limited to) activating/deactivating peripheral devices, adjusting equipment operational values, updating information on one or more screens, playing a sound or voice recording, triggering the movement of mechanisms that control one or more processes.
[0024] In addition, the system comprises a Visualization, Analytics and Configuration Platform 16 that is protected by authentication. With this, authorized users can visualize the data transmitted by the sensors, and configure the operation of the a Data Normalization and Correlation Engine 12, the Pattern Matching, Classification & Anomaly Detection Engine 14 and the Notifications & Work Procedures Engine 18, which allows a user to customize how the system must treat the received data, evaluate patterns, classify and detect anomalies, and behave when one of the predecessors is identified: who is notified, via which channels and which commands must be sent to sensor devices while running the notifications flow. If automated, this system can automatically send commands to the sensor(s) 8 which can transmit control or operations commands to asset systems, such as turning off or on peripherals, redirecting the asset, or halting the asset completely pending repairs.
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[0027] Examples of data circulated through the cloud-based network is shown further in
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[0032] However, if a pattern match rule set exists to the data at 148, the pattern match algorithm is run at 150. If a pattern match is detected at 152, the Notifications & Work Procedures Engine 16 is activated at 154, otherwise the process ends at 168. Similarly, if a classifier model exists for the data at 156, the appropriate data classifier model is run at 158 and a pattern match is determined at 160. If there is a pattern match, the Notifications & Work Procedures Engine 16 is activated at 154, otherwise the process ends at 168. Finally, if the anomaly detection model exists at 162, the appropriate anomaly detection model is run at 164. A pattern match is queried at 166, and if there is a pattern match, the Notifications & Work Procedures Engine 18 is activated at 154, otherwise the process ends at 168.
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[0034] If the message contains instructions for activation of a new notification graph at 176 by the Pattern Matching and Anomaly Detection Engine 14 at 176, then a save instance of the new notification graph is created at 178. A new notification graph composed of nodes that execute specific actions, which may include sending a message through instant communication, executing a phone call, communicating with an external application, or enqueuing a new command to a sensor device. Next, an asynchronous message to trigger the expiration of the newly created graph if no positive feedback is received during its lifetime is scheduled at 180. The first node of the graph and its configured actions are run at 182, and an asynchronous message that will expire the current node if no positive feedback is received during its execution over a preconfigured period of time occurs at 184. The process then ends at 214.
[0035] If the message contains a response by a communications channel that was used by a current active node at 186 (“communications feedback”) instead, the received message is processed and actions are executed related to the received feedback at 188. Based on that feedback, the next execution node is identified at 190, is executed and its expiration is scheduled based on a user-configured period of time at 192, and the graph status is updated on the data store 4 at 194. The process then ends at 214.
[0036] If the message notifies the expiration of a current node at 196 instead, the graph is updated and the current node status is set to expired, disabling all possible executions and feedback that node could trigger at 198. A next default node is selected at 200. A default node is the one that is triggered in the event the current active node does not receive a positive feedback and, if it's found, the newly found node is executed and an expiration message of itself is scheduled based on a user-set period of time at 202 and the graph status is updated on the data store 4 at 204 and saved, or if no default node is identified, the graph status is updated. The process then ends at 214.
[0037] Finally, if the message that notifies the expiration of a graph at 206, the graph status is marked as expired, disabling all possible actions and node executions at 208. After that, post-processing tasks are executed and the final status of the graph is updated on the data store 4 at 210. The process then ends at 214.
[0038] Otherwise, if the message is unidentified, the process discards the message at 212 and the process ends at 214.
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[0040] By stepping through these processes and either automating actions after communications are received by the asset sensors or ensuring notifications are sent to the appropriate users, all possible fail-safes are ensured and best-case results are guaranteed that will prevent or mitigate damage or errors resulting from the activation or utilization of the assets.
[0041] The present invention can contribute to timely, more informed, automated management in Agribusiness, Mining, Manufacturing, Energy, Financials and Trading. Examples below indicate how embodiments of the present invention may be used in specific applications, however these are merely illustrations of the present invention at work, and the present invention is extremely customizable.
[0042] A first example includes a use in the agriculture industry. A client, such as a farm that has already deployed sensors 8 for collecting data (e.g. soil temperature and humidity at varying depths, crop size, UV radiation, pesticide levels in different zones of the property), and/or has access to weather monitoring station that measure wind speed, rain, humidity, atmospheric pressure, or other factors. The sensors 8 stream their measurements to the system's 2 data endpoint 10 where intelligence correlates the information and automatically produces responses or action plans customized per zone through a process such as that indicated in
[0043] Another example includes a mining operation. In recent years, mining companies have invested heavily in complementary devices/sensors to better monitor their operations. Unfortunately, because many such solutions are stand-alone systems and data analysis often occurs long after the fact, most companies have not been seeing big returns on their tech investments. The present system 2 automatically integrates these existing systems, applies intelligence to data through a determined algorithm and alerts operations managers of critical or dangerous situations in real time. In a preferred embodiment a mining operation sets up the present invention as a way to improve overall safety. The mine operation deploys different sensors 8 to monitor mine stability, and these sensors stream to the system's data endpoint 10 data about a displacement occurring on the mine walls in real time. When the displacement exceeds a certain amount over time as determined through a mathematical formula, the system 2 triggers a specific alert flow to a zone supervisor (end user 46). The supervisor has one minute to confirm course of action: to continue working or to cease operations. If the supervisor does not confirm within a minute, the escalation engine automatically moves the alert to the next decision-maker/makers with another action-confirmation request. If no answer is received after 5 minutes, warning sirens are activated in the work zone to indicate to workers that they need to evacuate because abnormal conditions were detected. With the present invention, alerts are immediate so that decisions can be immediate, thus potentially saving lives and preventing accidents.
[0044] A third example includes a manufacturing process. Anything that unnecessarily stops production in manufacturing is costly. To prevent such gratuitous losses, the present invention can be designed to intervene without halting production. To start, a manufacturing facility equipped with sensors 8 (such as conveyor status, idler temperature/speed, idler sound/alignment, robot-arm orientation/vibrations, etc) connects its systems and robot arms to the present system 2 so that vital signs can be transmitted through the process as described above. The system's 2 pattern matching and anomaly detection engine 14 analyze this streaming data, and if a pattern or anomaly is detected, the invention activates an alert flow that sends correction signals to the equipment (asset 6) in order to update operational parameters without disrupting operations. At the same time, the system 2 sends a dispatch order through the communications gateway 40 to the machinery operators with a report on findings and a request, if necessary, for further review of conditions and additional actions needed to correct the issue(s).
[0045] A fourth example includes the energy industry. An example industrial operation deploys sound, vibration and heat sensors 8 for its substation transformers (assets 6). Those sensors are connected by a wireless network 26 to the system 2, and they transmit reports on said measurements as often as it is deemed necessary or predetermined. The invention's anomaly detection neural network (e.g. the data normalization & correlation engine 12, pattern matching, classification & anomaly detection engine 14, and notification s& work procedures engine 18) correlates the signals for every transformed connection and scores the status. With that, abnormalities can be detected based on historical data and/or data from third party vendors 36 as relevant. When an anomaly is detected, an immediate notification is activated so that maintenance workers (end users 46) have the latest readings of transformer status and comparable data, as well as a work-procedure checklist to follow up on transformer status and, if needed, take further actions.
[0046] A fifth example includes the financial industry. A software system for monetary transactions requires authentication and face recognition to confirm a potential money transfer. The system 2 analyzes every transaction locally (on the same CPU or by a supplementary system) and when a potential fraud occurs, this system 2 streams the account number, location, device identification tag and other information to the invention data endpoint. Here, the present invention triggers an alert flow and notifies the account owner and account executive of the potential fraud by phone while sending an email to the account owner with a complete report and a photo of the person who tried to perform the transaction.
[0047] Finally, and similarly, the trading industry also includes examples of uses of the present invention. A forex trading station extracts real-time data from different currency pairs and streams the data to the invention data endpoint. The present invention's system 2 applies correlation with mathematical and statistical formulas including polynomial and linear interpolation and employs pattern matching to divulge potential transaction opportunities. When a transaction opportunity is detected, an opportunity index is established and sent to the owner of the trading account and/or account manager. The message requests a confirmation of the transaction in the form of immediate action: to either execute the trade or decline. If the opportunity index reaches a certain threshold and the user doesn't respond within a preset period of time, the alert flow system can be designed to send a command to the trading station to automatically execute the transaction and notify the user of this action.
[0048] It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.