Note: Descriptions are shown in the official language in which they were submitted.
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System and Method to Query for Machine Conditions
Background
[2] Industrial automation has increased in scope and refinement with time.
In general, industrial automation has focused on continuous processes
comprising a plurality of interacting machines. Heretofore, automation
has not been fully developed and/or utilized for improvement of
production and/or reliability of many independent machines.
[3] Machinery that operates in an outdoor environment, such as mining
trucks and mining shovels, has traditionally not been extensively
monitored. Further, environmental conditions such as temperature,
humidity, geological conditions, and grade of land can significantly
affect machinery that operates in an outdoor environment. Operating
large machinery can be expensive. Operators frequently do not control
machines at optimum speeds, engine RPMs, payloads, and/or in a
manner that resufts in optimal maintenance cosis. Operators
sometimes do not operate in a manner that avoids invalidation of
warrantees and/or maintenance contracts. On occasion, improper
operation of machines has resulted in accidents, injuries, and
sometimes even death.
[4] Conventional systems do not adequately collect or analyze data related
to machinery operation.
Summary
[5] Certain exemplary embodiments comprise obtaining and analyzing
data from at least one machine, such as a mining truck. User
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interfaces can be provided to automatically determine relationships
between variables associated with the mining truck. Via a user
interface, a user can select one or more sensors and/or a time period
to analyze and/or display information.
[6] Certain exemplary embodiments comprise a method comprising, at a
remote server, receiving representative data obtained from a set of
sensors associated with the machine. The representative data can be
transmitted in a record format comprising machine type, machine
identifier, sensor data, and/or time stamp information, etc. The
representative data can be stored in a memory device associated with
a server.
Brief Description of the Drawings
[7] A wide variety of potential embodiments will be more readily
understood through the following detailed description, with reference to
the accompanying drawings in which:
[8] FIG. 1 is a diagram of a remote analysis system 1000;
[9] FIG. 2 is a flow diagram of a method 2000 of collecting and
transmitting machine data;
[10] FIG. 3 is a flow diagram of a method 3000 of transmitting machine
information to a remote client;
[11] FIG. 4 is a flow diagram of a method 4000 of remote client data
management;
[12] FIG. 5 is a flow diagram of a method 5000 of remote client report
generation;
[13] FIG. 6 is a flow diagram of a method 6000 of rendering data by a
remote client;
[14] FIG. 7 is a flow diagram of a method 7000 of data analysis by a
remote client;
[15] FIG. 8 is a block diagram of a client information device 8000;
[16] FIG. 9 is a block diagram of a data form 9000 of data record
denoted as a telegram;
[17] FIG. 10 is a rendering 10000 modeling an auxiliary gauge display;
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[18] FIG. 11 is a rendering 11000 modeling an auxiliary temperature
display;
[19] FIG. 12 is a rendering 12000 modeling a chronology basic table;
[20] FIG. 13 is a rendering 13000 modeling a chronology cycle
breakout;
[21] FIG. 14 is a rendering 14000 modeling a chronology export to a
spreadsheet table;
[22] FIG. 15 is a rendering 15000 modeling a cycle distribution by time
and distance display;
[23] FIG. 16 is a rendering 16000 modeling a DC bus gauge display;
[24] FIG. 17 is a rendering 17000 modeling a DC bus plot display;
[25] FIG. 18 is a rendering 18000 modeling a diagnostic message list
and stats display;
[26] FIG. 19 is a rendering 19000 modeling a diagnostic message plot
display;
[27] FIG. 20 is a rendering 20000 modeling a driver's plot display;
[28] FIG. 21 is a rendering 21000 modeling a driver's screen display;
[29] FIG. 22 is a rendering 22000 modeling a general plot display;
[30] FIG. 23 is a rendering 23000 modeling a general screen display;
[31] FIG. 24 is a rendering 24000 modeling a left motor gauges
display;
[32] FIG. 25 is a rendering 25000 modeling a left motor plot display;
[33] FIG. 26 is a rendering 26000 modeling a message window
display;
[34] FIG. 27 is a rendering 27000 modeling a mine profiler display;
[35] FIG. 28 is a rendering 28000 modeling a power section
temperature display;
[36] FIG. 29 is a rendering 29000 modeling a power vs. ground speed
display;
[37] FIG. 30 is a rendering 30000 modeling a right motor gauges
display;
[38] FIG. 31 is a rendering 31000 modeling a right motor plot display;
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[39] FIG. 32 is a rendering 32000 modeling a service brake distribution
& breakout display;
[40] FIG. 33 is a rendering 33000 modeling a temperature stats - plot
and breakout display;
[41] FIG. 34 is a rendering 34000 modeling a tire monitor display;
[42] FIG. 35 is a rendering 35000 modeling a truck load distribution
display;
[43] FIG. 36 is a rendering 36000 modeliing a wheel motor speed v.
torque;
[44] FIG. 37 is a flowchart 37000 for a cl ient query;
[45] FIG. 38 is a rendering 38000 modeling query and/or visualization
response displays regarding a machine speed;
[46] FIG. 39 is a rendering 39000 modeling query and/or visualization
response displays of the present invention regarding a mining
truck bed position;
[47] FIG. 40 is a query and/or visualization response display 40000
regarding operation of a mining truck;
[48] FIG. 41 is a query and/or visualization response display 41000
regarding operation of a mining truck;
[49] FIG. 42 is a rendering 42000 of gau ge displays related to motion
of a mining truck;
[50] FIG. 43 is a rendering 43000 of gau ge displays related to motion
of a mining truck;
[51] FIG. 44 is a query and/or visualization response display 44000
regarding operation of a mining truck;
[52] FIG. 45 is a rendering 45000 of gau ge displays related to motion
and operation of a mining truck;
[53] FIG. 46 is a block diagram of an exemplary embodiment of a
machine data management system 46000;
[54] FIG. 47 is a flow diagram of an exernplary embodiment of a
machine data management method 47000; and
[55] FIG. 48 is a block diagram of an exemplary embodiment of an
information device 48000.
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Definitions
[56] When the following terms are used herein, the accompanying
definitions apply:
[57] accept - receive.
[58] Active X - a set of technologies developed by Microsoft Corp. of
Redmond, Washington. Active X technologies are adapted to
allow software components to interact with one another in a
networked environment, such as the Internet. Active X controls
can be automatically downloaded and executed by a Web
browser.
[59] action - a performance of a deed or act.
[60] activity - performance of a function.
[61] adapted - structured and configured.
[62] automatic - performed via an information device in a manner
essentially independent of influence or control by a user.
[63] Boolean expression - an expression that, upon proper
evaluation, results in a value of either true or false. Boolean
operators can comprise operators such as relational operators
(e.g., "less than", "<_" and/or">", etc.), "AN D", "OR", "XOR", "NOR",
"NAND", and/or NOT, etc.
[64] chart - a pictorial device used to illustrate quantitative
relationships.
[65] chronological - ordered according to a tirne of occurrence.
[66] chronology cycle breakout - data obtained during a particular
time period. For example, data obtained for a time period during
which a mining truck hauls a particular load of material.
[67] communicate - to exchange information.
[68] communicative coupling - linking in a manner that facilitates
communications.
[69] comparing - examining similarities or differences.
[70] component - a part of a larger whole.
[71] condition - existing circumstance.
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[72] cycle distribution diagram - a chart or graph rendering
information regarding elapsed times during a cycle. For example,
for a mining truck, a cycle can be an amount o# time spent hauling
a particular load. The cycle can comprise an amount of time
waiting for the mining truck to be loaded, an arnount of time spent
loading the mining truck, an amount of time du ring which the
mining truck is transporting a load, an amount of time dumping the
load, and/or an amount of time returning to a location for loading
the mining truck, etc.
[73] cycle time - a time period associated with loading a haulage
machine with an electric mining shovel.
[74] data - numbers, characters, symbols etc., that have no
"knowledge level" meaning. Rules for composing data are
"syntax" rules. Data handling can be automated.
[75] database - one or more structured sets of persistent data, usually
associated with software to update and query the data. A simple
database might be a single file containing many records, each of
which is structured using the same set of fields. A database can
comprise a map wherein various identifiers are organized
according to various factors, such as identity, physical location,
location on a network, function, etc.
[76] detection - an act of sensing or perceiving.
[77] direction of travel - a distance-independent angular measure of
transverse motion of an object relative to a poi nt of reference.
[78] duration - length of time.
[79] earthen - related to the earth.
[80] electrical - pertaining to electricity.
[81] electrical component - a device and/or systern associated with a
machine using, switching, and/or transporting electricity. An
electrical component can be an electric motor, transformer,
starter, silicon controlled rectifier, variable frequency controller,
conductive wire, electrical breaker, fuse, switch, electrical
receptacle, bus, and/or transmission cable, etc.
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[82] electrical performance - performance related to an electrical
component of a machine. For example, electrical performance
can relate to a power supply, power consumption, current flow,
energy consumption, electric motor functionality, speed controller,
starter, motor-generator set, and/or electrical wiring, etc.
[83] electrical - pertaining to electricity.
[84] electrical variable - a sensed reading relating to an electrical
component. For example, an'electrical power measurement, an
electrical voltage measurement, an electrical torque
measurement, an electrical motor speed measurement, an
electrical rotor current measurement, and/or an electrical
transformer temperature measurement, etc.
[85] environmental variable - a variable concerning a situation
around a machine. For example, in the case of an electric m ining
shovel, an environmental variable can be a condition of mate rial
under excavation, weather condition, and/or condition of an
electrical power supply line, etc.
[86] exporting - to send data from one computer program to another.
Exporting can often result in a data formatting change.
[87] failure - a cessation of proper functioning or performance.
[88] fast motion - at a faster rate than an event actually occurred .
[89] function of time - relating a variable to time so that for each time
there is an associated value of the variable. Charting a variable
as a function of time can result in a chart with a time axis.
[90] freeze - to stop the motion or progress.
[91] gauge - a graphical display rendering at least a value of a
variable. A gauge can provide indications of a maximum
acceptable value, a minimum acceptable value, and/or an
accepted operating range, etc. A gauge can comprise a digital
display, a status indicator for a discrete variable, a dial on an arc,
a bar chart, a pie chart, and x-y plot, a bar indicative of a discrete
change, and/or images representing a machine or sub-parts
thereof, etc.
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[92] graph - a pictorial device used to illustrate quantitative
relationships.
[93] graphing - rendering via a graph.
[94] graphical - a pictorial and/or charted representation.
[95] historical time period - a past interval of time for which data has
been collected.
[96] identifying - recognizing or detecting.
[97] identification - evidence of identity; something that identifies a
person or thing.
[98] information - data that has been organized to express concepts.
It is generally possible to automate certain tasks involving the
management, organization, transformation, and/or presentation of
information.
[99] information device - any general purpose and/or special purpose
computer, such as a personal computer, video game system (e.g.,
PlayStation, Nintendo Gameboy, X-Box, etc.), workstation, server,
minicomputer, mainframe, supercomputer, computer terminal,
laptop, wearable computer, and/or Personal Digital Assistant
(PDA), mobile terminal, Bluetooth device, communicator, "sma.rt"
phone (such as a Handspring Treo-like device), messaging
service (e.g., Blackberry) receiver, pager, facsimile, cellular
telephone, a traditional telephone, telephonic device, a
programmed microprocessor or microcontroller and/or periphe iral
integrated circuit elements, an ASIC or other integrated circuit, a
hardware electronic logic circuit such as a discrete element circuit,
and/or a programmable logic device such as a PLD, PLA, FPC;A,
or PAL, or the like, etc. In general any device on which resides a
finite state machine capable of implementing at least a portion of
a method, structure, and/or or graphical user interface described
herein may be used as an information device. An information
device can include well-known components such as one or more
network interfaces, one or more processors, one or more
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memories containing instructions, and/or one or more input/output
(I/O) devices, etc.
[100] Input/Output (I/O) device - the inputloutput (I/O) device of the
information device can be any sensory-oriented input and/or
output device, such as an audio, visual, haptic, olfactory, and/or
taste-oriented device, including, for example, a monitor, display,
projector, overhead display, keyboard, keypad, mouse, trackball,
joystick, gamepad, wheel, touchpad, touch panel, pointing device,
microphone, speaker, video camera, camera, scanner, printer,
haptic device, vibrator, tactile simulator, and/or tactile pad,
potentially including a port to which an I/O device can be attached
or connected.
[101 ] instructions - directions adapted to perform a particular operation
or function.
[102] load - an amount of mined earthen material associated with a
bucket and/or truck, etc.
[103] log - a record of events.
[104] machine - a device and/or vehicle adapted to perform at least
one task.
[105] machine performance variable - a property associated with an
activity of a machine. For example, a machine performance
variable can be machine position, tons loaded per bucket, tons
loaded per truck, tons loaded per time period, trucks loaded per
time period, machine downtime, electrical downtime, and/or
mechanical downtime, etc.
[106] machine-readable medium - a memory readable by an
information device.
[107] material - any substance that can be excavated and/or scooped.
[108] measurement - a value of a variable, the value determined by
manual and/or automatic observation.
[109] mechanical component - a device and/or system associated
with a machine that is not primarily associated with using,
switching, and/or transporting electricity. A mechanical
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component can be a bearing, cable, cable reel, gear, track pad,
sprocket, chain, shaft, pump casing, gearbox, lubrication system,
drum, brake, wear pad, bucket, bucket tooth, cable, and/or power
transmission coupling, etc.
[110] mechanical performance - performance related to a mechanical
component or system. For example, mechanical performance
can relate to a bearing, gearbox, lubrication system, drum, brake,
wear pad, bucket, bucket tooth, cable, power transmission
coupling, and/or pump, etc.
[111 ] mechanical variable - a sensed reading relating to a mechanical
component. For example, a bearing temperature measurement,
an air pressure measurement, machine load reactions, and/or
lubrication system pressure measurements, etc.
[112] memory device - any device capable of storing analog or digital
information, for example, a non-volatile memory, volatile memory,
Random Access Memory, RAM, Read Only Memory, ROM, flash
memory, magnetic media, a hard disk, a floppy disk, a magnetic
tape, an optical media, an optical disk, a compact disk, a CD, a
digital versatile disk, a DVD, and/or a raid array, etc. The memory
device can be coupled to a processor and can store instructions
adapted to be executed by the processor according to an
embodiment disclosed herein.
[113] mine - a site from which earthen materials can be extracted.
[114] mining truck - a motor vehicle adapted to haul ore extracted from
the earth.
[115] mining truck status indicators - an indication of a condition of a
mining truck.
[116] operational variable - a variable related to operating a machine.
For example, an operation variable can be a technique used by
an operator to accomplish a task with a first machine (e.g. a path
used to haul a load in an mining truck), technique of an operator
of a second machine used in conjunction with the first machine
(e.g. how a mine haul truck spots relative to an electric mining
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shovel), number of second machines assigned in conjunction with
the first machine, characteristics of second machines assigned in
conjunction with the first machine (e.g. size, load capacity,
dimensions, brand, and/or horsepower, etc.), production time
period length, operator rest break length, scheduled production
time for the machine, a cycle time, and/or a material weight, etc.
[117] operator - one observing and/or controlling a machine or device.
[118] over - with reference to.
[119] over a time period of a different duration - with reference to a
first time interval of a first length that is not the same as a second
time interval of a second length.
[120] packetized signal - electrical pulses representative of a collection
of digital data comprised of information and associated headers
transmitted over a packet-switching network.
[121] packets - a collection of digital data comprised of information and
an associated header transmitted over a packet-switching
network.
[122] panel - a surface containing switches and dials and meters for
controlling a device.
[123] part - component.
[124] pattern - a characteristic form.
[125] performance - an assessment. Performance can be measured
by a characteristic related to an activity.
[126] physical location - a tangible place where something exists
relative to a reference point.
[127] physical path - a tangible route followed, the route relative to a
reference point.
[128] predicting - prognosticating a future event.
[129] position - location relative to a reference point.
[130] predetermined standard - a value and/or range established in
advance.
[131 ] predetermined threshold - a limit established in advance.
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[132] processor - a hardware, firmware, and/or software machine
and/or virtual machine comprising a set of machine-readable
instructions adaptable to perform a specific task. A processor
acts upon information by manipulating, analyzing, modifying,
converting, transmifting the information to another processor or an
information device, and/or routing the information to an output
device.
[133] production data - information indicative of a measure relating to
an activity involving operation of a machine. For example, bucket
load weight, truck load weight, last truck load weight, total weight
during a defined production time period, operator reaction, and/or
cycle timer associated with the electric mining shovel, etc.
[134] providing - furnishing or supplying.
[135] pulldown menu - a menu in a graphical user interface, whose
title is normally visible but whose contents are revealed only when
the user activates it, normally by pressing the mouse button while
the pointer is over the title, whereupon the menu items appear
below the title.
[136] query - (v) to obtain information from a database responsive to a
structured request. (n) a structured request for information from a
database.
[137] radio button - a small outlined area, often round in shape, in a
graphical user interface. The outlined area is adapted to accept a
Boolean user-selection, usually by pointing and clicking a mouse
in the cell.
[138] real-time - substantially contemporaneous to a current time. For
example, a real-time transmission of information can be initiated
and/or completed within about 120, 60, 30, 15, 10, 5, and/or 2,
etc. seconds of receiving a request for the information.
[139] regarding - pertaining to.
[140] relationship - related to or correlated with.
[141 ] relative - considered in comparison to something else.
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[742] relative position of a bed - a location of a portion of a truck
adapted to haul materials relative to a plane defined by a
centerline of a plurality of wheels of the truck. A truck bed of a
truck can be raised to release a load of material:
[743] remote - in a distinctly different location.
[144] render - make perceptible to a human. For example data,
commands, text, graphics, audio, video, animation, and/or
hyperlinks, etc. can be rendered. Rendering can be via any visual
and/or audio means, such as via a display, a monitor, electric
paper, an ocular implant, a speaker, and/or a cochlear implant,
etc.
[145] report - a presentation of information in a predetermined format.
[146] representation - an image or likeness of something.
[147] representative data - a plurality of measurement data associated
with defined times. For example, representative data can be a
plurality of readings from sensor taken over a time period.
[148] request - an expression of a desire.
[149] reset - a control adapted to clear and/or change a threshold.
[150] responsive - reacting to an influence and/or impetus.
[151] retard torque - a moment of a force applied to slow an object's
rotation and/or linear motion in a predetermined direction. Also
equivalent to the product of an angular retard deceleration and a
mass moment of inertia of an object.
[ 152] scrollable field - an area of a graphical user interface adapted to
accept an input from a user, the input comprising a value
obtainable by placing a pointer over an arrow in the graphical user
interface thereby causing the value to increase or decrease.
[ 153] select - choose.
[154] sensor - a device adapted to measure a property. For example,
a sensor can measure pressure, temperature, flow, mass, heat,
light, sound, humidity, proximity, position, velocity, vibration,
voltage, current, capacitance, resistance, inductance, and/or
electro-magnetic radiation, etc.
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[155] set - a collection of distinct elements having specific common
properties.
[156] slow motion - at a slower rate than an event actually occurred.
[157] spreadsheet - software adapted to display, calculate, and/or
manipulate data and characterized by rows and columns.
[158] statistical parameter - calculated information regarding data.
Statistical parameters can comprise a count, sum, sub-total, total,
ratio, mean, average, running average, weighted average, mode,
median, maximum, minimum, local maximum, local minimum,
standard deviation, variance, control chart range, statistical
analysis of variance parameter, statistical hypothesis testing
value, and/or a deviation from a standard value, etc.
[159] status - information relating to a descriptive characteristic of a
device and or system. For example, a status can be on, off,
and/or in fault, etc.
[160] store - save information on a memory device.
[161]telegrams - data records. Telegrams related to a machine can
comprise a machine type, a machine identifier, machine data,
and/or a time stamp, etc.
[162] temperature reading - an indication of an objects' heat.
[163] time period - an interval of time.
[164]time stamp - data representative of when something occurred
temporally.
[165] transverse motion - a linear and/or curvilinear movement of an
object from a first point to a second point.
[166] truck identifier - a label adapted to specify a particular truck.
[167] truck load distribution - a plurality of actual truck payloads.
[168] truck type - an identifier indicative of a plurality of common traits
or characteristics associated with a truck and shared by other
trucks categorized therewith.
[169] user - a person interfacing with an information device.
[170] user interface - any device for rendering information to a user
and/or requesting information from the user. A user interface
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includes at least one of textual, graphical, audio, video, animation,
and/or haptic elements.
[171 ] user-selected - stated, provided, and/or determined by a user.
[172] value - an assigned or calculated numerical quantity.
[173] variable - a property capable of assuming any of an associated
set of values.
[174] velocity - speed.
[175] viewable - capable of being seen by.
[176] weight of a load hauled - an amount of material transferred.
Detailed Description
[177] FIG. 1 is a diagram of a remote analysis system 1000.
[178] FIG. 2 is a flow diagram of a method 2000 of collecting and transmitting
machine data.
[179] FIG. 3 is a flow diagram of a method 3000 of transmitting machine
information to a remote client.
[180] FIG. 4 is a flow diagram of a method 4000 of remote client data
management.
[181] FIG. 5 is a flow diagram of a method 5000 of remote client report
generation.
[182] FIG. 6 is a flow diagram of a method 6000 of rendering data by a
remote client.
[183] FIG. 7 is a flow diagram of a method 7000 of data analysis by a remote
client.
[184] FIG. 8 is a block diagram of a client information device 8000.
[185] FIG. 9 is a block diagram of a data form 9000 of data record denoted
as a telegram.
[186] FIG. 10 is a rendering 10000 modeling an auxiliary gauge display.
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[187] FIG. 11 is a rendering 11000 modeling an auxiliary temperature
display.
[188] FIG. 12 is a rendering 12000 modeling a chronology basic table.
[189] FIG. 13 is a rendering 13000 modeling a chronology cycle breakout.
[190] FIG. 14 is a rendering 14000 modeling a chronology export to a
spreadsheet table.
[191] FIG. 15 is a rendering 15000 modeling a cycle distribution by time and
distance display.
[192] FIG. 16 is a rendering 16000 modeling a DC bus gauge display.
[193] FIG. 17 is a rendering 17000 modeling a DC bus plot display.
[194] FIG. 18 is a rendering 18000 modeling a diagnostic message list and
stats display.
[195] FIG. 19 is a rendering 19000 modeling a diagnostic message plot
display.
[196] FIG. 20 is a rendering 20000 modeling a driver's plot display.
[197] FIG. 21 is a rendering 21000 modeling a driver's screen display.
[198] FIG. 22 is a rendering 22000 modeling a general plot display.
[199] FIG. 23 is a rendering 23000 modeling a general screen display.
[200] FIG. 24 is a rendering 24000 modeling a left motor gauges display.
[201] FIG. 25 is a rendering 25000 modeling a left motor plot display.
[202] FIG. 26 is a rendering 26000 modeling a message window display.
[203] FIG. 27 is a rendering 27000 modeling a mine profiler display.
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[204] FIG. 28 is a rendering 28000 modeling a power section temperature
display.
[205] FIG. 29 is a rendering 29000 modeling a power vs. ground speed
display.
[206] FIG. 30 is a rendering 30000 modeling a right motor gauges display.
[207] FIG. 31 is a rendering 31000 modeling a right motor plot display.
[208] FIG. 32 is a rendering 32000 modeling a service brake distribution &
breakout display.
[209] FIG. 33 is a rendering 33000 modeling a temperature stats - plot and
breakout display.
[210] FIG. 34 is a rendering 34000 modeling a tire monitor display.
[211] FIG. 35 is a rendering 35000 modeling a truck load distribution display.
[212] FIG. 36 is a rendering 36000 modeling a wheel motor speed v. torque.
[213] FIG. 37 is a flowchart 37000 for a client query;
[214] FIG. 38 is a rendering 38000 modeling query and/or visualization
response displays regarding a machine speed;
[215] FIG. 39 is a rendering 39000 modeling query and/or visualization
response displays of the present invention regarding a mining truck
bed position;
[216] FIG. 40 is a query and/or visualization response display 40000
regarding operation of a mining truck;
[217] FIG. 41 is a query and/or visualization response display 41000
regarding operation of a mining truck;
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[218] FIG. 42 is a rendering 42000 of gauge displays related to motion of a
mining truck;
[219] FIG. 43 is a rendering 43000 of gauge displays related to motion of a
mining truck;
[220] FIG. 44 is a query and/or visualization response display 44000
regarding operation of a mining truck;
[221] FIG. 45 is a rendering 45000 of gauge displays related to motion and
operation of a mining truck.
[222] FIG. 46 is a block diagram of an exemplary embodiment of a machine
data management system 46000. Machine data management system
46000 can comprise a machine 46100. In certain exemplary
embodiments, machine 46100 can be a mining truck, electric mining
shovel, mining drill, locomotive, automobile, front end loader, bucket
wheel excavator, pump, fan, compressor, and/or industrial process
machine, etc. Machine 46100 can be powered by one or more diesel
engines, gasoline engines, and/or electric motors, etc.
[223] Machine 46100 can comprise a plurality of sensors 46120, 46130,
46140. Any of sensors 46120, 46130, 46140 can measure, for
example: time, pressure, temperature, flow, mass, heat, flux, light,
sound, humidity, proximity, position, velocity, acceleration, vibration,
torque, retard torque, voltage, current, capacitance, resistance,
inductance, and/or electro-magnetic radiation, etc., and/or a change of
any of those properties with respect to time, position, area, etc.
Sensors 46120, 46130, 46140 can provide information at a data rate
and/or frequency of, for example, between approximately 0.1 and
approximately 500 readings per second, including all subranges and all
values therebetween, such as for example, approxirnately 100, 88, 61,
49, 23, 1, 0.5, and/or 0.1, etc. readings per second. Any of sensors
46120, 46130, 46140 can be communicatively coupled to an
information device 46160.
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[224] Information obtained from sensors 46120, 46130, 46140 related to
rnachine 46100 can be analyzed while machine 46100 is operating.
Information from sensors 46120, 46130, 46140 can relate to
performance of measurable parts of the electrical system, performance
of measurable parts of the mechanical system, measurable elements
relating to machine performance, performance of one or more
operators, environmental variables,, and/or performance of one or more
dispatch entities associated with machine 46100, etc. For example,
sensors 46120, 46130, 46140 related to machine 46100 can measure
a relative position of a bed of a truck, such as a mining truck. Sensors
46120, 46130, 46140 related to machine 46100 can measure a torque
such as a retard torque related to a machine, such as a mining truck.
[225] Dispatch entities can be associated with a dispatch system. The
dispatch system can be an information system associated with the
rnachine. The dispatch system can collect data from many diverse
rnachines, personnel, and/or entities and can formulate reports of
production associated with machine 46100, personnel and/or
rnanagement entities associated with the production, a location
receiving the production, and/or production movement times, etc.
Certain exemplary embodiments can collect information related to
rnachine 46100 through operator input codes.
[226] Information device 46160 can comprise a user interface 46170 and/or
a user program 46180. User program 46180 can, for example, be
adapted to obtain, store, and/or accumulate information related to
rnachine 46100. For example, user program 46180 can store, process,
calculate, and/or analyze information provided by sensors 46120,
46130, 46140 as machine 46100 operates and/or functions, etc. User
interface 46170 can be adapted to receive operator 46190 input and/or
render output to operator 46190, such as information provided by
and/or derived from sensors 46120, 46130, 46140 as machine 46100
operates and/or functions, etc.
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[227] Information device 46160 can be adapted to process information
related to any of sensors 46120, 46130, 46140. For example,
information device 46160 can detect and/or anticipate a problem
related to machine 46100. Information device 46160 can be adapted
to notify an operator 46190 with information regarding machine 46100.
[228] Any of sensors 46120, 46130, 46140, and/or information device 46160
can be communicatively coupled to a wireless transmitter and/or
transceiver 46150. Wireless transceiver 46150 can be adapted to
communicate data related to machine 46100 with a wireless receiver
and/or second transceiver 46200. Data related to machine 46100 can
comprise electrical measurements and/or variables such as voltages,
currents, resistances, impedances, and/or inductances, etc.;
mechanical measurements and/or variables such as torques, shaft
speeds, vibration amplitudes, vibration frequencies, and/or
accelerations, etc.; temperature measurements and/or variables such
as from a motor, bearing, and/or transformer, etc.; pressure
measurements and/or variables such as air and/or lubrication
pressures; production data and/or variables (e.g. weight and/or load
related data) such as dipper load, truck load, last truck load, shift total
weight; and/or time measurements; motion control measurements
and/or variables such as, for certain movable machine components,
power, torque, speed, and/or rotor currents; etc.
[229] A network 46300 can communicatively couple wireless transceiver
46200 to devices such as an information device 46500 and/or a server
46400. Server 46400 can be adapted to receive information
transmifted from machine 46100 via wireless transceiver 46150 and
wireless transceiver 46200. Server 46400 can be communicatively
coupled to a memory device 46600. Memory device 46600 can be
adapted to store information from machine 46100. Memory device
46600 can store information, for example, in a format compatible with a
database standard such as XML, Microsoft SQL, Microsoft Access,
MySQL, Oracle, FileMaker, Sybase, and/or DB2, etc.
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[230] Server 46400 can comprise an input processor 46425 and a storage
processor 46450. Input processor 46425 can be adapted to receive
representative data, such as data generated by sensors 46120, 46130,
46140, from wireless transceiver 46200. The representative data can
be transmitted responsive to a transmission rate selected by a
wirelessly receiving user. Storage processor 46450 can be adapted to
store representative data generated from sensors 46120, 46130,
46140 on memory device 46600. Server 46400 can receive
representative data from wireless transceiver 46200 in a telegram
and/or record format. Formatted records can comprise a machine
identifier, a machine type, machine data, and/or a time stamp, etc.
[231] Information device 46500 can cornmunicate with machine 46100 via
wireless transceiver 46200 and wireless transceiver 46150.
Information device 46500 can notify and/or render information for the
user via user interface 46520.
[232] Information device 46500 can comprise an input processor 46525 and
a report processor 46575. In certain exemplary embodiments, input
processor 46525 can be adapted to receive representative data, such
as data generated by and/or derived from sensors 46120, 46130,
46140. The representative data can be transmitted responsive to a
data transmission rate selected by a wirelessly receiving user. Report
processor 46575 can be adapted to render at least one report
responsive to received and/or representative data, such as data
obtained from, for example, mernory device 46600.
[233] Information device 46500 can be adapted to obtain and/or receive
information from server 46400 related to machine 46100. Information
device 46500 can comprise a user interface 46560 and/or a client
program 46540. Client program 46540 can, for example, be adapted to
obtain and/or accumulate information related to operating and/or
maintaining machine 46100.
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[234] Client program 46540 can be adapted to provide one or more user
interfaces 46560. Via user interface 46560, a user can be queried for
the user's input and/or desires, those desires can be provided to client
program 46540 and/or a remote program and/or device, such as server
46400, and/or the user can be provided with information and/or
notifications, etc.
[235] In certain exemplary embodiments, user-interface 46560 can comprise
any known hardware and/or software rendering technology. For
example, user interface 46560 can cornprise a pulidown menu, user-
selectable radio button, and/or scrollable field, etc., adapted to provide
information indicative of the user-selectable time period.
[236] Client program 46540 can be adapted, via user-interface 46560, to
accept a user-selected time period, such as a historical time period, for
obtaining information regarding one or more sensors such as sensors
46120, 46130, 46140. As another example, the user can be queried to
select one or more sensors and/or information regarding one or more
sensors, such as an identity, location, and/or type of sensor, etc.
[237] In certain exemplary embodiments, client program 46540 can be
adapted to render, i.e., play, annunciate, display, chart, and/or animate,
etc., information regarding the sensor, such as for the user-selected
time period. In certain exemplary ernbodiments, client program 46540
can be adapted to process, i.e., analyze, correlate, aggregate, classify,
interpolate, extrapolate, determine statistical parameters regarding,
and/or provide predictions regarding, etc., information regarding the
sensor from the user-selected time period. Client program 46540 can
be adapted to provide instructions adapted to render a representation
of an action of an operator of machine 46100. The action of the
operator can be related to a user-selected sensor for which information
is obtained.
[238] In certain exemplary embodiments, the user can specify a time interval
during which the information regarding the sensor from the user-
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selected time period is rendered and/or processed, etc. The duration
of the time interval during which the information regarding the user-
selected sensor from the user-selected time period is rendered and/or
processed can be different from the duration of the user-selected time
period.
[239] For the time interval, information regarding the user-selected sensor
can be rendered at a different rate that a rate at which the information
was obtained from the sensor. For example, the information regarding
the user-selected sensor can be played in slow motio n such as on a
representation of a gauge. In certain exemplary embodiments, the
information regarding the user-selected sensor can be played in fast
motion such as on a representation of a gauge. The representation of
the gauge can provide an analog or digital display and can comprise a
typical value, a typical range, a recommended maxim um value, and/or
a recommended minimum value, etc. In certain exernplary
embodiments, client program 46540 can be adapted to freeze a
displayed gauge at a point in time. The point in time can be
automatically determined and/or directly or indirectly by the user.
[240] In certain exemplary embodiments, a plurality of representations can
be rendered approximately simultaneously. For example, the plurality
of representations can comprise representations of analog gauges
rendering data from user-selected temperature senscors. In certain
exemplary embodiments, the plurality of representations can comprise
and/or group a plurality of representations of user-selected status
indicators. Status indicators can comprise informatiori regarding
whether a machine is operating, whether a particular component of the
machine is operating, whether a particular componen# of the machine
is operating properly, whether the machine is en route to a
maintenance entity, and/or whether the machine is in production, etc.
[241] In certain exemplary embodiments, client program 46Z40 can be
adapted to group the plurality of representations regarding
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automatically and/or user-selected indicators related to rnachine
46100. The plurality of representations can be grouped according to at
least a partial representation of a panel readable by an operator
associated with machine 46100. The plurality of representations can
be grouped such that an axis of a first representation of the plurality of
representations is parallel to an axis of a second representation of the
plurality of representations. The plurality of representations can be
digital and or analog in appearance.
[242] Client program 46540 can be adapted to chart, plot, anci/or graph the
information regarding the user-selected sensor for the user-selected
time period as a function of time. Certain exemplary em bodiments can
comprise graphing information regarding multiple user-s elected
sensors concurrently as a function of time. Graphing information
regarding sensors as a function of time can provide a user with a visual
tool to identify relationships between variables and to better understand
problems and/or failures. In certain exemplary embodirnents, client
program 46540 can automatically identify a relationship between
information related to a first sensor and information related to a second
sensor.
[243] Client program 46540 can be adapted to provide machine readable
instructions to render a map associated with a path of th e machine via
user interface 46560. The map can comprise elevation information,
grade and/or slope information, topographic information, and/or
indicate a relative position of the machine compared to an object
and/or point of reference. The map can comprise a representation
relating to the physical location, physical path, transverse motion,
and/or direction of travel of machine 46100. Client program 46540 can
be adapted to provide a rendering comprising an attempt to slow a
machine. The rendering can comprise and indication of an applied
retard torque and/or machine deceleration information.
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[244] Client program 46540 can be adapted to obtain information from the
database responsive to a received user request to render chronological
information via user interface 46560. In certain exemplary
embodiments, the chronological information can be rendered in the
form of a chronology table. The chronology table can comprise a
tabular representation of information related to machine 46100. The
chronology table can be sorted according to a time stamp comprised in
each data record. The chronology table can comprise user-selected
fields from the database. In certain exemplary embodiments, the
chronology table can comprise an automatically selected set and/or
subset of fields from the database related to machine 46100 or a
plurality of machines comprising machine 46100. In certain exemplary
embodiments, the chronological information can be rendered in the
form of a time line and/or a chronological log, which can comprise a
sequential representation of sensor data rendered and/or reported over
a predetermined and/or user-specified time interval.
[245] Client program 46540 can be adapted to render truck load distribution
information associated with the mining truck. The truck load
distribution information can be related to a user-selected sensor. The
truck load distribution information can comprise frequency data of load
weights grouped in one or more of a plurality of ranges of payloads
hauled by the truck.
[246] Client program 46540 can be adapted to render and/or process
information associated with the type of payload carried by a given
mining truck, such as whether the load is waste material, ore, off-grade
material, prime material, etc.
[247] Client program 46540 can be adapted to render and/or process
information associated with environmental conditions such as
temperature, barometric pressure, humidity, precipitation, dust
conditions, fog, etc.
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[248] Client program 46540 can be adapted to render and/or process
information associated with operational conditions such as a time
and/or location of a blasting event, operator identity, dispatcher identity,
shovel identity.
[249] FIG. 47 is a flow diagram of an exemplary embodiment of a data
management method 47000 for a machine. Data management method
47000 can be used for reporting, rendering, processing, improving,
optimizing, predicting, and/or analyzing information regarding
operations and/or maintenance related to a machine involved in
activities such as mining, driving, and/or manufacturing, etc. At activity
47100, data can be received at an information device associated with
the machine. In certain exemplary embodiments, the information
device can be local to the machine. The information device can be
adapted to store, process, filter, correlate, transform, compress,
analyze, report, render, process, and/or transfer the data to a first
wireless transceiver, etc.
[250] In certain exemplary embodiments the data can comprise an
initialization file. The initialization file can be transmitted to and/or
received by a server that can be remote from the machine. The
initialization file can comprise identification information related to the
machine. The initialization file can comprise, for example, a moniker
associated with the machine, a type of the machine, an address of the
machine, information related to the transmission rate of data originating
at the machine, a transmission scan interval, log directory, time of day
to start a log file, and/or information identifying the order in which data
is sent and/or identification information relating to sensors associated
with the machine from which data originates.
[251] At activity 47200, the data can be transmitted. The data can be
transmitted via the first wireless transceiver to the second wireless
transceiver. The second wireless transceiver can transmit the
information via a wired and/or wireless connection to at least one
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wirelessly receiving information device to be stored, viewed, and/or
analyzed by at least one wirelessly receiving user. In certain
exemplary embodiments, transmitted data can be routed and/or
received by a remote server communicatively coupled to, for example,
the second wireless transceiver via a network.
[252] Data can be transmitted at a rate received at an apparatus and/or
system associated with the machine and adapted to adjust
transmissions from the machine responsive to the transmission rate.
The transmission rate can be received from a second information
device remote from the machine and/or the wirelessly receiving user.
The transmission rate can be related to a transmission rate between at
least the first wireless transceiver and the second wireless transceiver,
and/or a sampling rate associated with data supplied from at least one
sensor to the first wireless transceiver. The user can specify a
transmission rate via a rendered user interface on an information
device. In certain exemplary embodiments, the transmission rate can
be selected via the rendered user via, for example, a pull down menu,
radio button, and/or data entry cell, etc.
[253] In certain exemplary embodiments, transmitted data can be received at
an information device remote from the machine. The information
device can receive data transmitted via a first wireless transceiver
associated with the machine and a second wireless transceiver remote
from the machine. In certain exemplary embodiments, the information
device can be adapted to receive the data indirectly via a memory
device. The information device can be adapted to integrate information
from a plurality of sources into a database. Integrating information can
comprise associating data values from a plurality of sources to a
common time clock.
[254] In certain exemplary embodiments, the data can comprise information
relating to a status of the machine. The status of the machine can
comprise, for example, properly operating, shut down, undergoing
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scheduled maintenance, operating but not producing a product, and/or
relocating, etc. The status of the machine can be provided to and/or
viewed by the user via a user interface.
[255] In certain exemplary embodiments, data communication can be
validated. For example, the first wireless transceiver can query and/or
test transmissions from the second wireless receiver in order to find,
correct, and/or report errors in at least one data transmission. In
certain exemplary embodiments, a user can be provided with a status
related to the data communication via a user interface based rendering.
[256] In certain exemplary embodiments, data from the machine can be
received at a server and/or an information device. The data can
comprise a plurality of values for a plurality of machine system
variables associated with one or more machine system components.
The plurality of machine system variables can comprise operational
variables, environmental variables, variables related to maintenance,
variables related to mechanical performance of the machine, and/or
variables related to electrical performance of the machine, etc. In
certain exemplary embodiments, the machine can be an electric mining
shovel. The plurality of machine system variables can comprise at
least one operational variable. In certain exemplary embodiments, the
at least one operational variable can be related to digging earthen
material. In certain exemplary embodiments, the at least one
operational variable can comprise non-binary values.
[257] In certain exemplary embodiments, data can be transmitted and/or
received from a machine dispatch entity that can comprise information
related to the actions of a machine dispatcher, haulage machines
associated with an excavation machine, equipment scheduling,
personnel scheduling, maintenance schedules, historical production
data, and/or production objectives, etc.
[258] At activity 47300, data can be stored by an information device. The
information device can store the data in a memory device. The data
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can be stored in a plurality of formats such as SQL, MySQL, Microsoft
Access, Oracle, FileMaker, Excel, SYLK, ASCII, Sybase, XML, and/or
DB2, etc.
[259] At activity 47400, the user can provide input such as a selection of a
sensor for which to display and/or analyze data.
[260] At activity 46500, the user can provide input such as a user-selected
time period over which data can be analyzed and/or rendered.
[261] At activity 47500, data can be queried. Certain exemplary
embodiments can be adapted to accept information from the user and
automatically create a Boolean expression adapted to query a
database for user-requested information. The user can select
parameters related to the Booleari expression using any of a plurality of
user interface elements such as radio buttons, scrolling menus, and/or
cells adapted to receive input, etc. For example, the user might desire
to obtain information regarding an engine temperature during a period
between 9 am and 11 am, resulting in a Boolean expression analogous
to "((Sensor 1 EQ `engine temp.') and (Time EQ (9:00 to 11:00))." As
another example the user might desire for information regarding engine
temperature and oil pressure when the engine temperature is above
250 degrees Fahrenheit, resulting in a Boolean expression analogous
to "((Sensor 1 EQ (`engine temp.' if > 250) and (Sensor 2 EQ `engine
oil pressure') and (Time EQ (9:00 to 11:00))." The Boolean expression
can be used to retrieve a plurality of query-corresponding records
comprised in the database.
[262] The data related to the machine can be parsed and or extracted from a
memory device. Queried data can be compared to a predetermined
threshold and/or pattern. The data can be summarized and/or reported
subsequent to the query. Querying the data can allow the wirelessly
receiving user to manipulate and/or analyze the data related to the
machine. In certain exemplary embodiments the data can be queried
using a Machine Search Language engine.
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[263] At activity 47600, a report can be rendered. The report can comprise a
summary of the data and/or exceptions noted during an analysis of the
data. The report can comprise information related to, for example,
machine locations, machine paths, actual torques, speeds, operator
control positions, dispatch data, production, energy use associated with
the machine, machine position, machine motion, and/or cycle times
associated with the machine, etc. The report can comprise information
related to the operation of the machine. For example, for a mining
shovel, the report can comprise information related to the mining
shovel digging, operating but not digging, propelling, idling, off line, total
tons produced in a predetermined time period, total haulage machines
loaded in the predetermined time period, average cycle time for a
hauling machine, average tons mined, and/or average haulage
machine loads transferred, etc. In certain exemplary embodiments, the
report can comprise a cycle distribution diagram. The cycle distribution
diaaram can provide a management entity with information relating to
comparative machine performance indications.
[264] Wherein the machine is a mining truck, the report can comprise
information related to a haul cycle time, material weight hauled, mining
shovel to which the mining truck is assigned, dispatch information,
and/or average loads transferred, etc. The report can provide
operating and/or maintenance entities with information related to the
machine; recommend a course of action related to the operation and/or
maintenance of the machine; historical and/or predictive information;
trends in data, machine production data; and/or at least one deviation
from an expected condition as calculated based upon the data; etc.
[265] I n certain exemplary embodiments, the data can be rendered and/or
updated via a user interface in real-time with respect to the sensing of
the physical properties underlying the data, and/or the generation,
collection, and/or transmission of the data from the machine. The user
interface can be automatically updated responsive to updates and/or
changes to the data as received from the machine. Data can be
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rendered via the user interface from a user selected subset of sensors
of a plurality of sensors associated with the machine. Data can be
rendered via the user interface from a user selected subset of data
points, such as, for example, every 8 th data point, every data point
having a value outside a predetermined limit, every data point
corresponding to a predetermined event, etc. The user can select a
time period over which historical data can be rendered via the user
interface. In this manner the user can, analyze historical events in
order to determine trends and/or assist in improving machine
operations and/or maintenance.
[266] In certain exemplary embodiments data from the machine can be
rendered via the user interface which can comprise a 2-dimensional, 3-
dimensional, and/or 4-dimensional (e.g., animated, or otherwise time-
coupled) schematic model of the machine. The schematic model of the
machine can assist the user in visualizing certain variables and/or their
effects related to the machine. The schematic model of the machine
can reflect a position of the machine relative to a fixed location,
geographical position, and/or relative to another machine, etc. The
schematic model can comprise proportionally accurate graphics and/or
quantitative and/or qualitative indicators of conditions associated with
one or more machine components. For a mining shovel, for example,
the plurality of machine components can comprise hoist rope length,
stick extension, and/or swing angles, etc. The rendering can comprise
graphical indicators of joystick positions and the status displays that an
operating entity can sense while running the machine. For a mining
truck the rendering can comprise a diesel engine, motor generator set,
electric wheel drive motors, transmission gear setting, steering setting,
retard setting, and/or truck bed position, etc. In this way, the rendering
can be adapted to show a mechanical response of the machine under
a given set of conditions and/or how the operating entity judges the
mechanical response. The rendering can comprise an electrical
response of the machine and/or how the operating entity judges the
electrical response. In certain exemplary embodiments, data rendered
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from the machine can comprise GPS based positioning information
related to the machine. The data can comprise information related to a
survey. For example, in a mining operation, mine survey information
can be integrated with positioning information related to the machine.
[267] The rendering can comprise production information related to the
machine. In the case wherein the machine is an electric mining shovel,
production information can comprise a bucket load weight, haulage
machine load weight, last haulage machine load weight, shift total
weight, and/or cycle timer value, etc. For a mining truck, production
information can comprise a truck load weight, hauled material tonnage
per shift, hauled material tonnage from a shovel, and/or cycle time for
hauling a load, etc. The rendering can comprise electrical information
such as, for example, readings from line gauges, power gauges, line
strip charts, power strip charts, and/or temperature sensors related to
an electrical component such as a transformer, etc. The rendering can
comprise mechanical information such as, for example, readings from
temperature sensors related to a mechanical component such as a
bearing, air pressure sensors, lubrication system pressure sensors,
and/or vibration sensors, etc.
[268] In certain exemplary embodiments data can be rendered via a user
interface in one or more of a plurality of display formats. For example,
data can be rendered on a motion strip chart, motion XY plot, and/or
motion gauge, etc. Data can be rendered on a chart comprising a
minimum and/or maximum pointer associated with the data. The
minimum and/or maximum pointer can provide a comparison of a value
of a process variable with a predetermined value thereby potentially
suggesting that some form of intervention be undertaken. Certain
exemplary embodiments can comprise a feature adapted to allow the
minimum and/or maximum pointer to be reset and/or changed. For
example, the minimum and/or maximum pointer can be changed as a
result of experience and/or a change in design and/or operation of the
machine. The minimum and/or maximum pointer can be changed by,
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for example, an operating entity, management entity, and/or
engineering entity, etc.
[269] A graph can be rendered comprising information from a user-selected
sensor. The graph can be of an X-Y plot wherein information from a
first sensor is plotted as a function of information from a second
sensor. For example, for a mining truck a chart indicating torque
relative to motor speed can be graphed. In certain exemplary
embodiments, information from a plurality of sensors can be charted
and/or graphed as a function of time. Plotting graphs comprising
information from a plurality of sensors can allow the user to identify
relationships between sensor information. The graph can be a
chronology cycle breakout wherein truck haulage cycle times can be
distributions can be plotted over a shift, a day, a plurality of shifts,
and/or a plurality of days, etc.
[270] The rendering can comprise elements of graphic user interface, such
as menu selections, buttons, command-keys, etc., adapted to save,
print, change cursors, and/or zoom, etc. Certain exemplary
embodiments can be adapted to allow the user to select a subset of
sensors and/or data associated with the machine to be rendered.
Certain exemplary embodiments can be adapted to allow the user to
select a time range over which the data is rendered. Certain
exemplary embodiments can be adapted to provide the user with an
ability to load and play log files via the rendering. Rendering
commands can include step forward, forward, fast forward, stop, step
back, play back, and/or fast back, etc. Additional features can be
provided for log positioning and/or zooming in and out relative to a
particular time period. Certain exemplary embodiments can comprise
a drop down box adapted to accept a user selection of time intervals
and/or a start time.
[271] The report can comprise, for example, a machine performance
variable; information related to performance of a dispatch entity, such
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as a mine dispatch entity; information related to performance of a
machine mechanical component; information related to performance of
an machine electrical component; information related to activities
involving the machine, such as digging activities in the case of an
electric mining shovel; information related to non-digging activities
involving the machine, such as operator training; and/or information
related to propelled motion of the machine; etc.
[272] At activity 47700, data can be compared to a standard. The standard
can be a predetermined threshold, value, limit, data point, and/or
pattern of data related to the machine. The standard, or metric, can be
determined. The standard can be a statistical parameter related to
least one of the machine system variables. Determining the standard
can provide information adapted to improve machine operation,
improve performance of a machine operating entity, improve
performance of a machine dispatching entity, improve machine
maintenance, and/or reduce machine downtime, etc. Comparing data
to a standard can, for example, determine a past, present, or
impending mechanical failure; electrical failure; operator error; operator
performance; and/or supervisor performance, etc. Comparing data to a
standard can be used to provide a machine alert related to the sensor
and/or data therefrom.
[273] In certain exemplary embodiments, values for one or more variables
can be compared. In certain exemplary embodiments, values for a
variable can be compared to a predeterm ined standard. For example,
a bearing vibration reading can be compared to a predetermined
standard vibration amplitude, paftern, phase, velocity, acceleration,
etc., the predetermined standard representing a value indicative of an
impending failure. Predicting an impending bearing failure can allow
proactive, predictive, and/or preventive maintenance rather than
reactive maintenance.
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[274] As another example, a production achieved via the machine can be
compared with a predetermined minimum threshold. If the production
achieved is less than the predetermined minimurn, a management
entity can be notified in order to initiate corrective actions. If the
production achieved is above the predetermined minimum by a
predetermined amount and/or percentage, the management entity can
be notified to provide a reward and/or investigate the causes of the
production achieved.
[275] As a further example, machine productivity can be compared to a
predetermined standard. For example, in a mining operation for
predetermined production period, tons mined can be compared to a
historical statistical metric associated with the machine. The machine
productivity comparison can provide a management entity with
information that can be adapted to improve performance related to a
machine operator, a dispatch entity, a maintenance entity, and/or an
operator associated with a related machine.
[276] As yet another example, an operating temperature for an electric motor
controller can be compared to a predetermined rnaximum. If the
operating temperature exceeds the predetermined maximum, a
maintenance entity can be notified that a cooling system has failed
and/or is non-functional. Repairing the cooling system promptly can
help prevent a failure of the electric motor controller due to
overheating.
[277] As still another example, an electric mining shovel idle time while
operating can be compared to a predetermined maximum threshold. If
the electric mining shovel idle time exceeds the predetermined
maximum threshold, a mine dispatch entity can be notified that at least
one additional haulage machine should be assigned to the electric
mining shovel in order to improve mine production.
[278] As still another example, a lubrication system pressure and/or use can
be compared to predetermined settings. If the lubrication system is
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down or not performing properly, an operational and/or maintenance
entity can be notified. Tracking and/or comparing lubrication system
characteristics can be useful in predicting and/or preventing failures
associated with inadequate lubrication.
[279] In certain exemplary embodiments, variables from the machine data
can be correlated manually and/or automatically. For example, values
for two of the plurality of machine system variables can be
mathematically analyzed in order to determine a correlation between
those variables. Determining a correlation between variables can, for
example, provide insights into improving machine operations and/or
reducing machine downtime.
[280] In certain exemplary embodiments, the server and/or information
device can determine a trend related to at least one of the machine
system variables. The trend can be relative to time and/or another
machine system variable. Determining the trend can provide
inforrnation adapted to improve machine design, improve machine
operation, improve performance of a machine operating entity, improve
performance of a machine dispatching entity, improve machine
maintenance, and/or reduce machine downtime, etc.
[281] In certain exemplary embodiments, two correlated variables associated
with the machine can be analyzed. In embodiments wherein the
machine is an electric mining shovel, the two correlated variables can
be non-load-related and/or non-positional variables related to the
electric mining shovel.
[282] Analyzing variables associated with the machine can comprise utilizing
a pattern classification and/or recognition algorithm such as a decision
tree, Bayesian network, neural network, Gaussian process,
independent component analysis, self-organized map, and/or support
vector machine, etc. The algorithm can facilitate performing tasks such
as pattern recognition, data mining, classification, and/or process
modeling, etc. The algorithm can be adapted to improve performance
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and/or change its behavior responsive to past and/or present results
encountered by the algorithm. The algorithm can be adaptively trained
by presenting it examples of input and a corresponding desired output.
For example, the input might be a plurality of sensor readings
associated with a machine component and an experienced output a
failure of a machine component. The algorithm can be trained using
synthetic data and/or providing data related to the component prior to
previously occurring failures. The algorithm can be applied to almost
any problem that can be regarded as pattern recognition in some form.
In certain exemplary embodiments, the algorithm can be implemented
in software, firmware, and/or hardware, etc.
[283] Certain exemplary embodiments can comprise analyzing a vibration
related to the machine based on values from at least one vibration
sensor. The values can relate, for example, to a time domain,
frequency domain, phase domain, and/or relative location domain, etc.
The values can be presented to the pattern recognition algorithm to
find patterns associated with impending failures. The values can be
normalized, for example, with respect to a frequency and/or phase of
rotation associated with the machine. The values can be used to
obtain dynamic information usable in detecting and/or classifying
failures.
[284] Failures associated with the machine can be preceded by a condition
such as, for example, a changing tolerance, imbalance, and/or bearing
wear, etc. The condition can result in a characteristic vibration
signature associated with an impending failure. In certain exemplary
embodiments, the characteristic vibration signature can be discernable
from other random and/or definable patterns within and/or potentially
within the values.
[285] Certain exemplary embodiments can utilize Fourier transforms and/or
frequency normalization of the values. For example, frequency
variables associated vvith power spectral densities can be scaled to
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predetermined frequencies. Fourier transforms and/or scaling
frequency variables can provide clearer representations of certain
chronological and/or spectral patterns.
[286] Vibration sensor readings can be sampled and processed at constant
and/or variable time intervals. Certain exemplary embodiments can
demodulate the vibration sensor readings. In certain exemplary
embodiments, a frequency spectrum can be computed via a Fourier
transform technique. The pattern recognition algorithm can be adapted
to recognize patterns in the frequency spectrum to predict an
impending machine component failure.
[287] The pattern recognition algorithm can comprise a plurality of heuristic
rules, which can comprise, for example, descriptive characteristics of
vibration patterns associated with a failure of the component of the
machine. The heuristic rules can comprise links identifying likely
causes, diagnostic procedures, and/or effects related to the failure. For
example, the heuristic rules can be adapted to adjust maintenance,
machine, and/or personnel schedules responsive to detecting an
impending failure.
[288] Certain exemplary embodiments can monitor the machine while the
machine is operating_ Machine analysis functions can evaluate events
associated with the rnachine. Machine analysis functions can
determine causes of events and/or conditions that precede one or
more events, such as a failure. Received data can be analyzed to
detect average, below average, and/or above average performance
associated with the rnachine. The information associated with the
machine can be correlated with the dispatch system. In certain
exemplary embodiments, applications can be customized towards
individualized needs of operational units associated with the machine,
such as a mine.
[289] At activity 47800, a failure can be detected. The failure can be
associated with a mechanical and/or electrical component of the
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machine. For example, the mechanical failure can relate to a bearing,
wear pad, engine, gear, and/or valve, etc. The electrical failure can
relate to a connecting wire, motor, motor controller, starter, motor
controller, transformer, capacitor, diode, resistor, and/or integrated
circuit, etc. The failure can be automatically detected via comparing
sensor data to a predetermined threshoici and/or via automatically
recognizing a pattern in sensed and/or caiculated data associated with
the machine.
[290] At activity 47900, a user can be alerted. The user can be local to the
machine and/or operating the machine. I n certain exemplary
embodiments, the user can be the wirelessly receiving user, the
dispatch entity, a management entity, and/or a maintenance entity.
The user can be automatically notified to schedule and/or perform a
maintenance activity associated with the machine.
[291] In certain exempiary embodiments, a management entity associated
with the machine can be notified of infornnation related to the machine.
The management entity can be notified of certain comparisons
associated with activity 3500 and/or resu tts associated with activity
3600. Notifying the management entity can allow for corrective action
to be taken to avoid lower than desired performance. Notifying the
management entity can provide the management entity with
information usable to improve performance related to the machine.
[292] In certain exemplary embodiments, a maintenance entity associated
with the machine can be notified, such as regarding a problem,
scheduled maintenance and/or unscheduled maintenance associated
with the machine. Notifying the maintenance entity can provide for
prompt repair and/or prompt scheduling of repair associated with the
machine. Information obtained via activity 3600 can provide
information usable in improving preventa#ive maintenance related to
the machine.
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[293] FIG. 48 is a block diagram of an exemplary embodiment of an
information device 48000, which in certain operative embodiments can
comprise, for example, information device 46160, server 46400, and
information device 46500 of FIG. 46. Information device 48000 can
comprise any of numerous well-known compon ents, such as for
example, one or more network interfaces 48100, one or more
_ processors 48200, one or more memories 48300 containing
instructions 48400, one or more input/output (I/O) devices 48500,
and/or one or more user interfaces 48600 coupled to I/O device 48500,
etc.
[294] In certain exemplary embodiments, via one or r-nore user interfaces
48600, such as a graphical user interface, a user can view a rendering
of information related to a machine.
[295] Still other embodiments will become readily apparent to those skilled in
this art from reading the above-recited detailed description and
drawings of certain exemplary embodiments. It should be understood
that numerous variations, modifications, and aciditional embodiments
are possible, and accordingly, all such variatiorts, modifications, and
embodiments are to be regarded as being withi n the spirit and scope of
the appended claims. For example, regardless of the content of any
portion (e.g., title, field, background, summary, abstract, drawing figure,
etc.) of this application, unless clearly specified to the contrary, there is
no requirement for the inclusion in any claim of the application of any
particular described or illustrated activity or elernent, any particular
sequence of such activities, or any particular interrelationship of such
elements. Moreover, any activity can be repeated, any activity can be
performed by multiple entities, and/or any element can be duplicated.
Further, any activity or element can be excluded, the sequence of
activities can vary, and/or the interrelationship of elements can vary.
Accordingly, the descriptions and drawings are to be regarded as
illustrative in nature, and not as restrictive. Moreover, when any
number or range is described herein, unless clearly stated otherwise,
CA 02563468 2008-05-26
that number or range is approximate. When any range is described
herein, unless clearly stated otherwise, that range includes all values
therein and all subranges therein.
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