# US 2023/0054784 A1 · Aggregate and correlate data from different types of sensors > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0054784 A1 - Document ID: US20230054784A1 - Status: Published application - Kind: A1 - Application number: 17/406,309 - Filed: 2021-08-19 - Published: 2023-02-23 - Earliest claimed: 2021-08-19 - Assignees: Rockwell Automation Technologies, Inc. - Applicants: Rockwell Automation Technologies, Inc. - Inventors: Chirag Malkan; Kyle Crum; David Vasko; Steven T. Haensgen; Bijan SayyarRodsari; Katherine Sokolnicki; Yongyao Cai - Web page: https://patentgrep.com/patent/US20230054784A1 ## CPC - G05B 23/0283: {Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] (preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06)} - G08B 21/182: {Level alarms, e.g. alarms responsive to variables exceeding a threshold} - G01M 99/005: {Testing of complete machines, e.g. washing-machines or mobile phones (testing of machine parts G01M13/00; testing of electric apparatus or components G01R31/50)} - G05B 19/4155: characterised by program execution, i.e. part program or machine function execution, e.g. selection of a program - G05B 23/0235: {based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold} - G05B 2219/31449: Monitor workflow, to optimize business, industrial processes - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - G08B: SIGNALLING SYSTEMS, e.g. PERSONAL CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS - G01M: TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR ## Abstract A method for correlating data from sensors includes receiving sensor information from a plurality of sensors of an industrial operation. Sensor information from component sensors is used for functionality of a component of the industrial operation and sensor information from additional sensors monitor conditions of a portion of the industrial operation different from the component. The method includes deriving, using the sensor information, correlations between component sensors and additional sensors and deriving a baseline signature from the sensor information and the correlations. The baseline signature encompasses a range of normal operating conditions. The method includes identifying an abnormal operating condition based on a comparison between additional sensor information and the baseline signature. The sensor information is used differently for functionality of the component than for deriving the correlations and baseline signature and identifying the abnormal operating condition. The method includes sending an alert with the abnormal operating condition. ## Claims ### Claim 1 A method comprising: receiving sensor information from a plurality of sensors of an industrial operation, wherein sensor information from one or more component sensors of the plurality sensors is used for functionality of a component of the industrial operation and sensor information from one or more additional sensors of the plurality of sensors monitor conditions of a portion of the industrial operation different from the functionality of the component; deriving, using the sensor information, correlations between sensor information of sensors of the one or more component sensors and of the one or more additional sensors; deriving a baseline signature from the sensor information and the correlations, the baseline signature encompassing a range of normal operating conditions; identifying an abnormal operating condition of the industrial operation based on a comparison between additional sensor information from the plurality of sensors and the baseline signature, wherein the sensor information is used differently for functionality of the component than for deriving the correlations and baseline signature and identifying the abnormal operating condition; and sending an alert comprising the identified abnormal operating condition. ### Claim 2 (depends on 1) The method of claim 1, wherein the component is a first component and sensor information from the additional sensors is used for functionality of one or more additional components of the industrial operation. ### Claim 3 (depends on 1) The method of claim 1, wherein the one or more additional sensors are general purpose sensors independent of functionality of the component. ### Claim 4 (depends on 1) The method of claim 1, wherein identifying the abnormal operating condition comprises identifying a trend in the additional sensor information that varies from the baseline signature. ### Claim 5 (depends on 1) The method of claim 1, wherein: deriving the correlations from the sensor information comprises using a machine learning algorithm to derive the correlations; and/or identifying the abnormal operating condition of the industrial operation comprises using a machine learning algorithm to identify a trend in the additional sensor information that deviates from the baseline signature. ### Claim 6 (depends on 1) The method of claim 1, wherein deriving the baseline signature from the sensor information comprises identifying one or more contexts of the industrial operation, the one or more contexts each for different normal operating conditions in the industrial operation and wherein identifying the abnormal operating condition of the industrial operation comprises identifying additional sensor information outside of the one or more contexts. ### Claim 7 (depends on 1) The method of claim 1, wherein the baseline signature comprises one or more thresholds and identifying the abnormal operating condition of the industrial operation comprises identifying that the additional sensor information exceeds at least one of the one or more thresholds. ### Claim 8 (depends on 1) The method of claim 1, wherein the sensor information comprises location information for at least a portion of the plurality of sensors and identifying the abnormal condition comprises using the location information to identify a source of the abnormal condition. ### Claim 9 (depends on 1) The method of claim 1, further comprising synchronizing the sensor information from the plurality of sensors. ### Claim 10 (depends on 1) The method of claim 1, wherein the plurality of sensors include sensors of different types. ### Claim 11 (depends on 10) The method of claim 10, wherein the plurality of sensors sense one or more of temperature, humidity, vibration, current, voltage, motion, acoustic noise, strain, movement, odor, and pressure. ### Claim 12 (depends on 1) The method of claim 1, wherein the sensor information includes command information about operational commands issued to equipment of the industrial operation. ### Claim 13 (depends on 1) The method of claim 1, wherein the component exports sensor information from the one or more component sensors to a computing device external to the component. ### Claim 14 A system comprising: a plurality of sensors sensing conditions on equipment of an industrial operation, wherein one or more component sensors of the plurality of sensors provide sensor information for functionality of a component of the industrial operation and one or more additional sensors of the plurality of sensors provide sensor information to monitor conditions of a portion of the industrial operation different from the functionality of the component; a sensor module configured to receive sensor information from the plurality of sensors; a correlation module configured to derive, using the sensor information, correlations between sensor information of sensors of the one or more component sensors and of the one or more additional sensors; a baseline module configured to derive a baseline signature from the sensor information and the correlations, the baseline signature encompassing a range of normal operating conditions; an error module configured to identify an abnormal operating condition of the industrial operation based on a comparison between additional sensor information from the plurality of sensors and the baseline signature, wherein the sensor information is used differently for functionality of the component than for deriving the correlations and baseline signature and identifying the abnormal operating condition; and an alert module configured to send an alert comprising the identified abnormal operating condition, wherein said modules comprise one or more of hardware circuits, a programmable hardware device and executable code, the executable code stored on one or more computer readable storage media. ### Claim 15 (depends on 14) The system of claim 14, wherein one or more of: the component is a first component and sensor information from the additional sensors is used for functionality of one or more additional components of the industrial operation; and the one or more additional sensors are general purpose sensors independent of functionality of the component. ### Claim 16 (depends on 14) The system of claim 14, wherein: the correlation module deriving the correlations from the sensor information comprises using a machine learning algorithm to derive the correlations; and/or the error module identifying the abnormal operating condition of the industrial operation comprises using a machine learning algorithm to identify a trend in the additional sensor information that deviates from the baseline signature. ### Claim 17 (depends on 14) The system of claim 14, wherein the baseline module deriving the baseline signature from the sensor information comprises identifying one or more contexts of the industrial operation, the one or more contexts each for different normal operating conditions in the industrial operation and wherein the error module identifying the abnormal operating condition of the industrial operation comprises identifying additional sensor information outside of the one or more contexts. ### Claim 18 (depends on 14) The system of claim 14, further comprising a synchronization module configured to synchronize the sensor information from the plurality of sensors. ### Claim 19 (depends on 14) The system of claim 14, wherein the plurality of sensors sense one or more of temperature, vibration, current, voltage, motion, acoustic noise, strain, movement in a 3-dimensional space, odor, and pressure. ### Claim 20 A computer program product comprising a computer readable storage medium having program code embodied therein, the program code executable by a processor to: receive sensor information from a plurality of sensors of an industrial operation, wherein sensor information from one or more component sensors of the plurality sensors is used for functionality of a component of the industrial operation and sensor information from one or more additional sensors of the plurality of sensors monitor conditions of a portion of the industrial operation different from the functionality of the component; derive, using the sensor information, correlations between sensor information of sensors of the one or more component sensors and of the one or more additional sensors; derive a baseline signature from the sensor information and the correlations, the baseline signature encompassing a range of normal operating conditions; identify an abnormal operating condition of the industrial operation based on a comparison between additional sensor information from the plurality of sensors and the baseline signature, wherein the sensor information is used differently for functionality of the component than for deriving the correlations and baseline signature and identifying the abnormal operating condition; and send an alert comprising the identified abnormal operating condition.