Abstract:
A method and system for providing efficient repair of mining equipment includes providing an electronic device having a camera, a microphone and geolocation determining hardware and software. The method includes capturing an image and sound of the mining equipment in need of repair along with the geolocation of the mining equipment, and automatically dispatching an electronic message including the captured image, sound and geolocation data to an electronic address of a service center. The automatic dispatch of the electronic message occurs without need of further action by an operator of the electronic device, and the timing of the dispatch is instantly, or when a network connection becomes available. In one embodiment of the invention the electronic device is integrated in a wearable device such as a hard hat.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention pertains to methods and systems for gathering and distributing field data relating to mining equipment and infrastructure used in mining operations to optimize reliability and to minimize down time, and particularly distributing field equipment data including images and sounds. 
       BACKGROUND OF THE INVENTION 
       [0002]    Mining is highly reliant on heavy equipment, and other assets that are required for removing, transporting and processing earth, minerals and mining products. Often equipment utilizes consumable parts, such as drill bits, belts, hoses, gauges, connectors and numerous other components. These wear, fail, and periodically require replacement or repair. 
         [0003]    This equipment is subject to great loads, and less-than-optimal operating conditions. Virtually any piece of equipment can wear, requiring maintenance, or fail. In most cases the cost of repair is significant, but the costs of downtime and production delays in mining operations are critical, and must be adequately managed. 
         [0004]    Typically, when equipment fails a site engineer is called to inspect the equipment and assess the problem. After the inspection, the site engineer returns to an area where a phone conversation can be had. 
         [0005]    A discussion with an equipment part supplier or other service professional may yield questions such as name tag information for the machine to be repaired, and a detailed description of the part that has failed. This process takes time and may require the site engineer to return to the failed equipment several times to gather the information required to order any parts required for repair. If the site is remote, much time can be lost. The time lost during this process costs the mining operation significantly. 
         [0006]    These same issues arise in various industries including energy and telecommunications. Power plants have generation and transmission components that require maintenance, and the costs of down-time are significant. Telecommunications systems require transmission infrastructure maintenance and repair. Any effort to minimize down-time has significant value, particularly for equipment that requires repairs and maintenance in hard to reach locations. 
         [0007]    What is desired is a way of streamlining processes of repairing and maintaining equipment in the field to minimize downtime of industrial operations, including mining operations. 
       SUMMARY OF THE INVENTION 
       [0008]    A method of providing efficient repair of capital equipment includes providing an electronic device having a camera and a microphone, and enabling a service technician to use the electronic device to capture an image and sound of capital equipment, such as mining equipment, in need of repair. 
         [0009]    The method includes programming the electronic device with software and employing the software to automatically dispatch an electronic message including the captured image or sound, or both, to an electronic address of a service center. 
         [0010]    The automatic dispatch of an electronic message occurs whenever an image is captured, so one instruction or command to the electronic device results in both the capture of an image and the dispatch of an electronic message. 
         [0011]    In an alternate embodiment, the image includes a series of images in the form of a video clip and sound associated with the video clip. In another alternate embodiment, a sound clip capture feature is enabled so that the entry of a single command i.e. sound capture, results in both capturing a sound for a period of time and automatically transmitting a digital representation of the sound, for example in a .wav formatted file. The period of time may be pre-determined to be in the range of 5-10 seconds for example, or it may be modified by a user operating the electronic device. 
         [0012]    In one embodiment, the electronic device has a user interface. The user interface includes a send button, which is either a physical button, or a button programmed to appear on a touch screen of the electronic device. The method includes enabling actuation of the send button to automatically dispatch an electronic message including the captured image and sound file. In this embodiment, the capture and dispatch of the image occur in separate steps. The electronic address to which the electronic message is pre-programmed. This saves time by enabling a user to skip any step requiring selection of an electronic address. 
         [0013]    In one embodiment, the capital equipment includes a tag having details describing the equipment, i.e. serial number, or model number. The electronic device is programmed to read serial numbers and model numbers from the tag. Additionally, where the tag has a bar code, such as a data matrix bar code, then the data from the bar code is read by the electronic device and communicated in the electronic message. 
         [0014]    In an alternate embodiment the capital equipment includes a Radio Frequency Identification Tag (RFID), and the electronic device includes an RFID tag reader. Accordingly, data stored on the RFID tag, i.e. serial number and model number, are automatically communicated with the image or sound clip from the electronic device. 
         [0015]    Preferably the electronic address for the data transmitted from the electronic device is that of a service center having a server. The transmitted data is processed by the service center server. The service center server includes bar code reading capability to read bar codes from images communicated to the server from the electronic device. The service center server, in an alternate embodiment, is configured with software to identify and convert raw data from an RFID tag format into useable data that can be stored in a customer relations management (CRM) database in operative communication with the server. 
         [0016]    In one embodiment, the server automatically detects bar codes in images and converts the data stored on the bar code into alpha-numeric data readable by a service center technician. 
         [0017]    In another embodiment, the server includes optical character reading (OCR) software, and the server utilizes the OCR to read an image of the tag and convert the information on the tag into alpha-numeric data, for storage in the CRM database. 
         [0018]    Thus any optically read data from images of a tag, and the tag image, is stored in the customer relations database and stored along with associated data. Associated data includes a customer name, company, location, service history, and field technician contact information. 
         [0019]    The server includes a service center database connected in operative communication with a library database. Data from the alpha-numeric tag, bar code, or RFID tag enables the service center database to assemble data from the library database, wherein the assembled data includes a parts list for the capital equipment to be repaired. The service center database communicates the parts list to the service center technician to enable parts to be ordered and services scheduled. 
         [0020]    In one embodiment, electronic device includes a microphone, and the method includes recording sounds made by the capital equipment in need of repair, and automatically dispatching an electronic message including the sounds to an electronic address of a service center. 
         [0021]    The electronic device is a smart phone in one embodiment of the invention, in another embodiment of the invention the electronic device is a wearable device. 
         [0022]    The wearable device is a smart wristwatch in one variation of the invention. In another embodiment, the wearable device is a pair of smart glasses such as Google™ Glasses. In yet another embodiment, the electronic device is integrated into a hard hat, having stereoscopic cameras and a microphone. 
         [0023]    The present invention includes a system for troubleshooting capital equipment including mining equipment, transmission lines, bridges, and power plants. The system includes a service center server having a server. 
         [0024]    A customer relations management (CRM) database is in operative communication with the server. A library database is in operative communication with the customer relations management (CRM) database. The library database stores parts lists, part numbers and images of parts for the capital equipment. 
         [0025]    An electronic device used by a field technician is in operative communication with the server via a cellular network, satellite network, or other wireless network. The electronic device including a camera and microphone for capturing images and sounds of the capital equipment. The electronic device includes a data communication terminal for communicating data captured by the electronic device to the server. 
         [0026]    The electronic device is programmed to store an electronic address of a service center, and to automatically dispatch images from the camera, and sounds recorded by the microphone, to the service center server. Images captured by the camera are automatically dispatched to the service center. 
         [0027]    The electronic device include Global Positioning System (GPS) components or similar location system hardware that enables GPS communication capability for determining location of the electronic device, and the capital equipment location where images, sound and other data are collected. The data communications terminal automatically communicates the location of the electronic device to the service center server with any electronic communication between the electronic device and the server. The service center server utilizes the location of the electronic device to determine the customer, the company, the location, and other data, and associates the images and sounds in the electronic communication with a customer in the customer relations management (CRM) database. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]      FIG. 1  shows a system in accordance with the present invention. 
           [0029]      FIG. 2  shows a detailed layout of a system in accordance with the present invention. 
           [0030]      FIG. 3  shows a flowchart of a method in accordance with the present invention. 
           [0031]      FIG. 4  shows an image of a bridge inspector inspecting a truss bridge. 
           [0032]      FIG. 5  shows an image of capital equipment on location in a mining operation. 
           [0033]      FIG. 6  shows an electronic device and interface. 
           [0034]      FIG. 7  shows a hard hat with an integrated electronic device, cameras and a microphone. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]      FIG. 1  is a system in accordance with the present invention. The system is generally designated with the reference numeral  10 . The system  10  includes portable electronic devices. Examples of electronic device used with the present system, include a smart phone  12  and a tablet computer  14 . Further examples of electronic devices in accordance with the present invention include wearable electronic devices including glasses, wrist watch-style devices and hard hats having integrated electronics and a camera. 
         [0036]    The system  10  also includes a network  18  such as a cellular data network, or satellite-based data network, capable of communicating data over distances of many miles. The system  10  includes a database server  16  that includes a customer relations management database, and communicates with a library database. The network  18  enables operative communication between the electronic devices and the server  16 . 
         [0037]    Although a smart phone  12  and tablet computer  14  are shown in  FIG. 1 , it can be appreciated that numerous devices can be adapted for use with the present invention. For example a gauss meter can be adapted with a camera, microphone and communications interface for use with the power distribution system diagnostics and testing. Devices for measuring current, impedance and voltage can also be adapted for use with the present invention. Further, devices with vibration sensing capability, including an accelerometer can be use with the present invention. These are just a subset of examples of a limited number of devices that can be adapted for use with the present invention. 
         [0038]      FIG. 2  shows a system generally designated with the reference numeral  20 . The system  20  includes an electronic device  22  capable of audio and video data input or capture, and communication of this audio and video data. Preferably the electronic device is a programmable computing device, capable of running applications for managing image capture and audio recording. The electronic device  22  communicates via a network  24  to the server  26 . 
         [0039]    In one embodiment of the invention, the electronic device  22  is programmed with an application to capture a still image and automatically communicate the image via the network  24  to the server  26 . Preferably, the electronic device  22  includes a stored email address or text message number address where any captured image is automatically routed. In this way a busy field technician may snap a picture with the electronic device  22  and that image is automatically routed to the server  26 . 
         [0040]    Images communicated by the electronic device  22 , in one embodiment of the invention, are tagged with geo location information. Such geo location information can be embedded directly into an image or video, or can be streamed as a data packet in conjunction with image and video. In addition to geo location information, other information such as the electronic identification of the electronic device, the user, the company, and the particular business unit, can be embedded in the image or video, or streamed as a data packet in conjunction with the image or video. 
         [0041]    Context recognition software can be programmed into the electronic device  22  so that images of a machine, equipment, or other asset can be readily identified from the images captured by the electronic device  22 . Context recognition software can also be programmed into the server  26  to achieve context recognition capability, including readily identifying a machine, part or other asset to enable maintenance, analysis or repair of that machine, part or other asset. 
         [0042]    The system  20  also includes a contacts relations management (CRM) database. The CRM database stores images  36 , videos  38  and sound clips  40 , along with customer data. Customer data includes contact information for field technicians and equipment locations for that customer. The server  26  is a general purpose computer including a processor  28 , a user interface  30  and a communication interface  32 . The communication interface communicates with a library database  34  that details parts lists, part names, images and maintenance manuals associated with equipment operated by the customers stored in the CRM database. 
         [0043]    In one embodiment the electronic device  22  includes a means for determining the location of the device. When an image or sound is automatically communicated from the electronic device  22  to the server  26 , the location of the device  22  is also included with the communication. Accordingly, the server  26  uses the location data to automatically identify the customer. Other ways of identifying the customer, include the phone number or email address associated with the electronic device user. In any event the customer is identified and the customer&#39;s field service technician electronic address is also identified and stored in the CRM database of the server  26 . 
         [0044]    Once the images  36 , videos  38  and sound clips  40 , or any subset of these, is associated with a customer in the CRM database of the server  26 , the server  26  accesses the library database to populate the CRM database with useful information regarding the customer and equipment operated by the customer. Additionally, particular maintenance and service records can also be linked with the CRM database of the server  26 . The server  26  can then automatically dispatch a communication to a service center that can immediately plan to resolve maintenance and repair issues in response to the images  36 , videos  38  and sound clips  40  (or subset thereof) dispatched by the electronic device  24 . 
         [0045]    Importantly the steps described above can happen before the field service technician operating the electronic device  22  can complete a detailed phone call. 
         [0046]    A response to the electronic device  22  is automatically generated by the server  26  and dispatched to the electronic device  22 . The response can confirm receipt of any previous communication i.e. image, video or sound. The response can also ask questions, including pre-formatted questions such as: “Is there an equipment name plate?”. The response can be managed by machine learning based on context recognition, or generated by human intervention. 
         [0047]    The term “automatically communicate” includes storing data, images, and sounds for communication until such a time when a data network is within range. For example, in a mine that is far underground there may not be satellite, cellular or other network connectivity. When an image or video is captured, and a signal is automatically communicated by the electronic device  22 , however, the communication is delayed until the electronic device  22  is within range of, and connects to, an appropriate data network. 
         [0048]      FIG. 3  shows a method in accordance with the present invention, generally designated with the reference numeral  38 . The method  38  is utilized with the system of  FIG. 2 , and this description makes reference to elements described in  FIG. 2 . 
         [0049]    The method  28  includes the step  40  of providing an electronic device  22  with a camera. In one embodiment, the method  38  includes providing an electronic device  22  having a camera and a microphone. In a further embodiment, the electronic device  22  may be equipped with electronic testing components for measuring electrical resistance, electromagnetic field strength and direction, for measuring current, voltage, vibrations and other items that may be relevant to inspecting and maintaining equipment. 
         [0050]    The method  38  includes the step  42  of capturing an image, or sound, of a maintenance object, such as mining equipment, bridge, power generator, or other heavy equipment that is not readily moved. The step  44  determines whether the equipment or object has a tag by electronically reading the image to determine whether it is a picture of a tag or not. The step  44  can be performed by the electronic device  22 , or by the server  26 . 
         [0051]    Where the maintenance object has a tag, the step  46  captures an image of the tag. The step  40  utilizes optical character recognition (OCR) algorithms to read the image and convert it into readable text. The step  50  utilizes the readable text and employs the server  26  to electronically search for maintenance object parts in the library database  34 . Any text read from images is automatically includes in the CRM database in conjunction with images communicated by the electronic device  22 . 
         [0052]    The step  52  queries price and availability for the particular maintenance object, various parts associated therewith, and provides a display of a parts list to the CRM database, which can be readily accessed by a service professional. 
         [0053]    The step  54  automatically sends images and other data to the electronic address of a service professional, who has access to the CRM database  26 . The step  56  sends a notification from the CRM database  26  to the electronic device  22  indicating that the image was received by the server  26 . 
         [0054]    Step  58  provides additional feedback to the electronic device  22 , including questions. The step  58  is initiated by a service professional and is dispatched by the service professional to the electronic address of the electronic device  22 . The step  60  resolves feedback and questions though an iterative communication process that could include email, text and voice communications. 
         [0055]    Step  62  schedules maintenance time and place and dispatches a maintenance team to the location of the electronic device  22 , or the maintenance object. 
         [0056]      FIG. 4  shows a field technician inspecting a bridge  64 . The bridge  64  is part of a transportation system such as rail, or roadways. Because the location of the inspection location is remote, i.e. above ground, efficiency demands that the field technician visit the location of inspection a minimum number of times. The field technician utilizes the electronic device  2  of  FIG. 2  of the present invention to automatically send an image of the portions of the bridge  64  to be repaired or maintained in accordance with the method of  FIG. 3 . 
         [0057]      FIG. 5  shows turbines  66  operating as part of a mining operation, or a power generation operation. The turbines are readily imaged by the electronic device  22  of the present invention. When non-routine vibration and sound is generated by the turbines  66 , or other elements, these sounds can be recorded and transmitted to a service professional in accordance with the method of  FIG. 3 , and using the electronic device of  FIG. 2 . 
         [0058]    Although the turbines  66  are shown enclosed in a building, the present invention can be utilized on various turbines, pumps, and even wind turbines that are located outdoors. 
         [0059]      FIG. 6  shows an electronic device  22  having an interface  68  and being programmed with an application. The interface  68  in this ebodiment includes a touch screen. The application, when activated, displays two buttons  70  and  72  displayed. The button  70  is labeled image, and the button  72  is labeled video/sound. 
         [0060]    The electronic device  22  includes a camera  74  and selection of the button  70  by a user automatically captures an image using the camera  74 , and automatically communicates the image via the network  24  to the server  26  (see  FIG. 2 ). Preferably, the image is automatically communicated without any other action by the user other than a one-click selection of the button  70 , or the button  72 . Each selection of the button  70 , or  72  communicates an image, or video, respectively. 
         [0061]    Although the camera  74  is shown on the same side of the electronic device  22  as the interface  68 , it can be appreciated that the camera  74  can be on an opposing side of the electronic device  22  so that activation of the camera  74  can capture an image seen by the user at a distance from the electronic device  22 , while the user faces and operates the electronic device  22 . 
         [0062]    The electronic device  22  includes a microphone  76  and selection of the button  72  automatically captures a video with the camera  74  and sound with the microphone  76 . The video is of limited duration, the duration being pre-programmed by the electronic device  22 . In one embodiment the video is of duration of between 3-20 seconds, and in another embodiment the duration of the video is between 5-10 seconds. In yet another embodiment, the application has a settings button that activates a dashboard interface to enable a user to program the duration of any video captured and sent by the application. 
         [0063]    In one embodiment of the invention, the geolocation of the electronic device  22  can be determined on-line or off-line by the electronic device  22 . Whenever a new image is captured the application automatically tags it with location data from a Geolocation Application Programming Interface (API) proposed by W3C in their Geolocation APA Specification and related recommendations of 24 Oct. 2013, published at W3.org. Whenever the electronic device reaches a location having network coverage, electronic device application automatically uploads images and other to the server. The server uses geolocation data to construct links that point to a mapping service using the library database. A service technician can immediately determine location of the user of the electronic device  22 , and map relevant machinery known to be at that location. The service technician can make recommendations for repair of the machine imaged by the electronic device, and also make recommendations for period maintenance of other known machines at that location, as well as suggestions for consumable parts and supplies. This represents an efficient way to minimize down time of machines at the location of the electronic device  22 . 
         [0064]    Benefits of the present invention are numerous and the invention can be readily adapted for use in parts management system, plant operations system and enterprise asset management systems. The invention is useful for a variety of industries including mining, telecommunications, power generation and distribution systems. Power generation systems include including coal, solar, wind, nuclear, geothermal and other power generation systems. 
         [0065]    Equipment reliability is of great importance to these industries and applications. The present invention helps to develop and maintain appropriate maintenance strategies by equipment type, reduced equipment failure through prioritization of inspection and maintenance of key assets. Improving plant and equipment reliability results from a comprehensive understanding of equipment health and plant operations. The present invention can also improve decision making and more informed business cases and long-term forecasting for capital investment projects. 
         [0066]      FIG. 7  shows a hard hat  80  including an electronic device mounted within the hard hat  80  in accordance with the present invention. The hard hat  80  includes a protective outer shell. 
         [0067]    Dual cameras  84  and  82  mount on the protective shell to enable stereoscopic imaging. Stereoscopic imaging enables two channels of video feed to achieve redundancy and the ability to determine precise distances of objects imaged when the video stream generated by the dual cameras  84  and  82  is analyzed. 
         [0068]    A microphone  86  mounts on a lateral side of the hard hat  80 . The microphone  86  and the dual cameras  84  and  82  attach in operative communication with the electronic device. Preferably the dual cameras  84  and  82 , and the microphone are hard wired to the electronic device. 
         [0069]    The electronic device is a module enclosed within a water and impact resistant case. The electronic device is fixed within the hard hat  80 , being attached within the protective shell. 
         [0070]    The cameras  82  and  84  and the microphone  86  to enable wires to extend through the hard hat to enable stereoscopic viewing and sound capture data to be communicated to the electronic device. 
         [0071]    A flexible suspension element attaches within the helmet  80  that comfortably supports the hard hat on the head of a wearer. The electronic device, in this embodiment has an interface. The interface, in this embodiment, has an integrated operation switch  88  controllable by the wearer. The switch  88  is preferably located on the flexible suspension element. In an alternate embodiment, the electronic device is voice-activated and the electronic device includes a voice recognition module in communication with the microphone to enable voice-activation and control. 
         [0072]    For example, simple voice commands can be pre-configured or selected by the user. Commands may include “camera on”, “microphone on”, “camera zoom”, “camera off”, “snap shot” and “microphone off” for controlling the camera operation, microphone operation, camera object resolution among other traditional camera and microphone functions. 
         [0073]    In one embodiment a telephonic cellular or radio module is integrated within the helmet  80  and in electronic communication with the microphone  86  to enable a wearer to engage in telephonic communication while collecting video images with the cameras  82  and  84 . 
         [0074]    While the present invention is described in terms of various embodiments, these are by way of example. The true scope of the invention is described by the appended claims.