Systems and methods for data collection and signal conditioning in an industrial environment
Systems and methods for data collection and signal processing are disclosed, including a plurality of variable groups of analog sensor inputs, the analog sensors operationally coupled to an industrial environment. The inputs of the sensors may be received by an analog crosspoint switch, where the signals are monitored, data collection may be adaptively scheduled, front end signal conditioning may occur, and a noise value determined.
1. A method for data collection in an industrial environment, the method comprising:
receiving, at an analog crosspoint switch, analog data from a plurality of variable groups of analog sensor inputs;
monitoring the analog data from the plurality of variable groups of analog sensor inputs;
adaptively scheduling data collection of the analog crosspoint switch; and
determining a noise value selected from the noise values consisting of: ambient noise, local noise, and vibration noise.
2. The method of claim 1 , further comprising performing internet protocol (IP) front-end end signal conditioning to improve a signal-to-noise ratio of at least one of the analog sensor inputs.
3. The method of claim 1 , further comprising predicting a state of at least one of a component or a process of the industrial environment in response to the determined noise value.
4. The method of claim 1 , further comprising utilizing a transfer function to determine a relative phase of a first one of the analog sensor inputs to a second one of the analog sensor inputs.
5. A data collection and processing system, comprising:
variable groups of sensor inputs, each of the variable groups of sensor inputs operationally coupled to an industrial environment;
a switch comprising multiple sensor channels configured to receive long blocks of high-sampling rate data from one or more of the variable groups of sensor inputs; and
a data management feature that includes multiple routes communicatively coupling the variable groups of sensor inputs to the multiple sensor channels, wherein the switch is configured to use hierarchical templates to perform one of creating or adjusting one of the multiple routes.
6. The data collection and processing system of claim 5 , further comprising a controller configured to store calibration data and a maintenance history of one or more sensors associated with the variable groups of sensor inputs.
7. The data collection and processing system of claim 5 , wherein the switch is further configured to provide a continuously monitored alarm in response to one of more inputs from the variable groups of sensor inputs.
8. The data collection and processing system of claim 5 , wherein the switch is configured to perform internet protocol (IP) front-end end signal conditioning to improve a signal-to-noise ratio of one or more of the sensor channels.
9. A data collection and processing system, comprising:
variable groups of sensor inputs, each of the variable groups of sensor inputs operationally coupled to an industrial environment;
a switch comprising multiple sensor channels configured to receive long blocks of high-sampling rate data from one or more of the variable groups of sensor inputs; and
a data management feature that includes a controller configured to perform intelligent management of data collection frequency bands obtained by one or more of the variable groups of sensor inputs.
10. The data collection and processing system of claim 9 , wherein the controller is configured to store calibration data and a maintenance history of one or more sensors associated with the variable groups of sensor inputs.
11. The data collection and processing system of claim 9 , wherein the switch is further configured to provide a continuously monitored alarm in response to one or more inputs from the variable groups of sensor inputs.
12. The data collection and processing system of claim 9 , wherein the switch is configured to perform internet protocol (IP) front-end end signal conditioning to improve a signal-to-noise ratio of one or more of the sensor channels.
13. A data collection and processing system, comprising:
variable groups of sensor inputs, each of the variable groups of sensor inputs operationally coupled to an industrial environment;
a switch comprising multiple sensor channels configured to receive long blocks of high-sampling rate data from one or more of the variable groups of sensor inputs; and
a data management feature that includes a controller comprising a neural net expert system, wherein the neural net expert system is configured to perform intelligent management of data collection frequency bands obtained by at least one of the variable groups of sensor inputs.
14. The data collection and processing system of claim 13 , wherein the controller is configured to store calibration data and a maintenance history of one or more sensors associated with the variable groups of sensor inputs.
15. The data collection and processing system of claim 13 , wherein the switch is further configured to provide a continuously monitored alarm in response to one or more inputs from the variable groups of sensor inputs.
16. The data collection and processing system of claim 13 , further comprising at least one additional switch, and wherein each of the switches comprises a corresponding complex programmable logic device (CPLD), each CPLD configured to control a corresponding switch.
17. A data collection and processing system, comprising:
variable groups of sensor inputs operationally coupled to an industrial environment;
a switch communicatively coupled to the variable groups of sensor inputs; and
a controller configured to continuously monitor data from multiple variable groups of sensor inputs, wherein continuously monitoring comprises adaptively scheduling data collection of the switch.
18. The data collection and processing system of claim 17 wherein the controller is further configured to determine a noise value from one or more of an ambient noise, a local noise, or a vibration noise; and wherein the controller is further configured to predict a state of at least one of a component or a process of the industrial environment in response to the determined noise value.
19. The data collection and processing system of claim 17 , wherein the controller is further configured to use smart route changes based on at least one of incoming data or alarms, and to provide simultaneous dynamic data from the multiple variable groups of sensor inputs in response to the one of incoming data or alarms.
20. The data collection and processing system of claim 17 , wherein the controller is further configured to perform machine pattern recognition based on a fusion of a selected plurality of the variable groups of sensor inputs.
21. The data collection and processing system of claim 17 , wherein the controller is further configured to utilize a transfer function to determine a relative phase of a first one of the sensor inputs to a second one of the sensor inputs.
22. The data collection and processing system of claim 17 , wherein the controller is further configured to perform machine pattern analysis based on a selected plurality of the variable groups of sensor inputs, and wherein the machine pattern analysis comprises anticipated state information for the industrial environment.
23. The data collection and processing system of claim 17 , further comprising:
a cloud-based policy automation engine comprising at least one of:
a sensor selection of the variable groups of sensor inputs;
a sensor deployment of variable groups of sensor inputs;
a sensor fusion of the variable groups of sensor inputs; or
a data storage profile of the variable groups of sensor inputs; and wherein the controller is further configured to selectively communicate at least a portion of the data of the multiple variable groups of sensor inputs to a cloud-based storage.
24. The data collection and processing system of claim 17 , wherein the controller is further configured to implement a self-organizing data marketplace, the self-organizing data marketplace including at least a portion of the data from the variable groups of sensor inputs.
25. The data collection and processing system of claim 24 , wherein the controller is further configured to implement a self-organizing data pool based on at least one of: sensor utilization, data utilization, or yield metrics.
26. The data collection and processing system of claim 17 , wherein the controller is further configured to train an artificial intelligence (AI) model based on industry-specific feedback relating to the industrial environment.
27. A method for data collection in an industrial environment, the method comprising:
receiving, at a switch, data from one or more variable groups of sensor inputs;
monitoring the data from the one or more variable groups of sensor inputs;
adaptively scheduling data collection at the switch; and
determining one or more noise values including one of an ambient noise, a local noise, or a vibration noise.
28. The method of claim 27 , further comprising performing internet protocol (IP) front-end end signal conditioning to improve a signal-to-noise ratio of the one or more variable groups of sensor inputs.
29. The method of claim 27 , further comprising predicting a state of at least one of a component or a process of the industrial environment in response to one or more of the determined noise values.
30. The method of claim 27 , further comprising utilizing a transfer function to determine a relative phase between a first sensor input from one of the variable groups of sensor inputs and a second sensor input from one of the variable groups of sensor inputs.