System for rule management, predictive maintenance and quality assurance of a process and machine using reconfigurable sensor networks and big data machine learning

A method of maintaining interoperability in an industrial process having rule management, predictive maintenance and quality assurance aspects, comprising:

• a) configuring a plurality of sensors attached to a machine operating as a part of the process for measuring information about the process and operation of the machine;
• b) configuring a server connected to the plurality of sensors over a wireless communication network for processing the plurality of information related to the process received from the plurality of sensors;
• c) configuring a controller in communication with the server, the controller being capable of controlling the process based data received from the server;
• d) receiving on a rule engine interface of the server a selection of data associated with the machine measuring information about the process machine operation;
• e) a program running in the server for forming automated rules from the data received from the plurality of sensors, the automated rules being applied for predictive maintenance and process quality assurance;
• f) mapping output from the controller for the process into a reconfigurable engine running the server for classifying predictive maintenance data and controller data to perform analytical processing;
• and
• g) extracting useful information from sensor data and performing an analytical processing for predictive maintenance and process quality assurance on the server.

A system for obtaining rule management, predictive maintenance and quality assurance information for an industrial process from sensor data, comprising:

• a) a plurality of sensors capable of being attached to a machine for measuring information associated with the industrial process and the machine operating as a part of the process;
• b) a server connected to the plurality of sensors over a wireless communication network, for processing the information related to the industrial process received from the plurality of sensors;
• c) a controller associated with the server, for controlling the industrial process based on data received from the server,
• d) a program running in the server and forming automated rules from the data received from the plurality of sensors, the automated rules being for predictive maintenance and process quality assurance;
• e) wherein output from the controller associated with the industrial process is mapped into a reconfigurable engine running in the server classifying predictive maintenance data and controller data to perform analytical processing on extracted information from the sensor data;
• f) wherein the analytical processing is for predictive maintenance and process quality assurance;
• and
• g) wherein the server includes multi-tier architecture for:
• i) calibrating the plurality of sensors based on an auto calibration signal;
• ii) base-lining the sensor data;
• and
• iii) calibrating a gauge associated with the predictive maintenance information.