Abstract:
A system for monitoring performance of a machine for detection of visible signs of failure, includes: a machine enclosure housing machine parts; at least one canal through the machine enclosure acting as a visual conduit for providing a view into the interior of the machine; a guide rail within the canal for moving a camera into the interior; an interface to the machine configured to receive images from the visual conduit; and a repair network for linking the interface to a monitoring center that provides for the repair of problems with the machine.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of, and claims priority to, U.S. patent application Ser. No. 13/052060, filed on Mar. 19, 2011, which is a division of, and claims priority from, U.S. application Ser. No. 12/330443, now U.S. Pat. No. 7,952,641, which claims priority from U.S. application Ser. No. 10/874,022, now U.S. Pat. No. 7,502,068. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention disclosed broadly relates to the field of machines and more particularly relates to the field of diagnosis of problems in machines. 
       BACKGROUND OF THE INVENTION 
       [0003]    When a machine breaks down, it may be difficult and expensive to repair because disassembly may be required to diagnose the problem. There is also a frequent delay in obtaining parts to replace those broken once the problem has been diagnosed. The resulting down time is also a problem. 
         [0004]    Remote monitoring of equipment needs different kind of sensors. Common sensors today include temperature sensors, weight sensors, position sensors, etc. The data from these sensors can be remotely viewed to diagnose the condition of the system. However, there are still situations where these sensors are not adequate to diagnose the problem and is necessary for a human being to open up the equipment and look at it. This process is time consuming and there needs to be a better way. The idea is to use imaging inside the equipment to handle situations that cannot be addressed by the above means. 
       SUMMARY OF THE INVENTION 
       [0005]    Briefly, according to the invention, a machine comprises an enclosure; a plurality of parts within the enclosure; and a visual conduit for providing a view inside of the enclosure for detection of visible signs of failure of the machine. The concept of a visual conduit encompasses a broad variety of devices including cameras inside the enclosure that provide images of the interior of the enclosure and alternatively selective transparency or translucence of the enclosure relative to at least some of the parts of the machine housed within the enclosure. 
         [0006]    According to another embodiment of the invention a method for designing a machine comprises the steps of: selecting a first material for an enclosure; and selecting a second material for one or more parts within the enclosure; wherein the selection of the materials permits viewing of the parts under certain conditions. 
         [0007]    According to another embodiment of the invention a system comprises an interface for receiving images from remote devices; one or more central servers for storing the images for further analysis using image processing techniques; and a transmitter for further distribution of the images to other destinations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    To describe the foregoing and other exemplary purposes, aspects, and advantages, we use the following detailed description of an exemplary embodiment of the invention with reference to the drawings, in which: 
           [0009]      FIG. 1  shows a machine with sensors according to the invention. 
           [0010]      FIG. 2  shows a highly-simplified depiction of a machine according to another embodiment of the invention. 
           [0011]      FIG. 3  shows a cross-section of a machine with parts made form materials with different properties. 
           [0012]      FIG. 4  shows a machine with parts made form materials with different properties wherein RF-tags are embedded in the parts to identify the materials. 
           [0013]      FIG. 5  shows system architecture according to the present invention. 
       
    
    
       [0014]    While the invention as claimed can be modified into alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention. 
       DETAILED DESCRIPTION 
       [0015]      FIG. 1  shows a highly-simplified depiction of a machine  100  with sensors according to the invention. The machine  100  comprises an enclosure or housing  101  for machinery  104 . In this embodiment, the sensors comprise a set of cameras  102 , all located within the machine enclosure  101  to capture images of the machinery  104 . Assume that the machine  100  is an expensive piece of equipment such as a printer, magnetic resonance imaging device or the like. In this case a set of parts  104  is malfunctioning. The camera  102  is used to diagnose the problem. In this case assume that the machinery  104  comprises mechanical moving parts and failures can be easily detected by obtaining images of the parts  104  by means of the camera  102  using the light  106  to illuminate the parts. Because the enclosure of the machine need not be opened during a diagnosis operation, the machine can continue to operate showing the cause of failure. Assume that the machine parts  104  are a set of gears and one of the gears is missing a cog. The images produced by the camera  102  are provided to a user outside the machine who can easily determine the cause of the failure. As will be appreciated, the light source  106  may not be required where the camera  102  obtains images using infrared radiation produced by the parts  104  when they are hot as a result of their operation. 
         [0016]    The camera  102  can be a still or preferably a video camera with flash, zoom, and other such features. It is preferably controlled by external controls  116 . The camera  102  can be mounted on a track  108  and coupled to a motor  114  that is controlled by the external controls  116 . The user is presented with the images provided by the camera  102  and can thus interactively control the orientation and movements of the camera to provide the desired images of the machine parts  104 . 
         [0017]    The camera  102  has a unique identifier (ID) and a wired or wireless link to the outside world for communication with a user. The unique identifier is transmitted to the outside world so that each machine can be identified from other nodes in the network. Alternatively, the camera  102  may be programmed to move automatically providing a set of images that may be stored and later viewed on demand to determine what caused a failure in the past. The light  106  can also be programmed to move automatically or can be moved manually by means of the external control apparatus  116 . 
         [0018]    An alternative image conduit is provided by a tube  110  having an internally reflective surface (preferably fiber optics) that transmits an image or images of the interior of the machine  100  to the outside. Such a tube  110  can include a camera and light as well. The tube is preferably flexible so that it can negotiate winding paths throughout the machine  100 . 
         [0019]    The cameras can be placed in locations where even highly obscured parts (such as part  112 ) can be imaged. 
         [0020]    Referring now to  FIG. 2 , there is shown a machine  200  according to another embodiment of the invention. In this embodiment, the visual conduit  202  includes a plurality of pathways or canals that are provided throughout the machine to provide images of its interior. As in the case depicted in  FIG. 1 , a canal  202  provides an image of the machine parts  204  to its users to assist in determining whether the parts are operating properly. A light source  206  provides illumination where necessary. Optional camera guide rails or paths  208  are provided in one of the canals  202  to allow for movement of a camera (not shown) to locations required for providing the desired images. Thus, a camera can be sent through the pathways  208  for providing images throughout the inside of the machine. 
         [0021]    Referring to  FIG. 3 , there is shown another embodiment of the invention wherein the visual conduit  202  includes a machine enclosure  302  made from a material that is transparent to a source of electromagnetic radiation (EMR)  300  at one or more frequencies such as x-ray frequencies. Thus the radiation source  300  provides x-rays that pass through the enclosure  302  relatively unimpeded but are substantially blocked by a machine part  304  that is made from a different material that is opaque to the EMR. The result is an image of the machine part  304  that can be captured at a sensor  306  outside the enclosure  302 . An example of a sensor is a film that is sensitive to x-rays. The sensor can be located inside the enclosure  302  and connected to the outside by a communication link to provide the images acquired. The film  306  can be optionally replaced by a sensor (such as charge-coupled devices) that detects the EMR that passes through enclosure  302 , and provides the image to the world outside the enclosure. 
         [0022]    Referring to  FIG. 4 , there is shown another embodiment of the invention wherein the machine enclosure  400  is made from a different material than the interior parts  402  and radio-frequency tags  410  are embedded in the parts  402  to provide an indication of the material from which they are made. An RF-tag reader (not shown) can be used from outside the enclosure  402  to read the information stored in the RF-tag  410 . This provides user information that can be used to determine the properties of the materials so that the user can select an appropriate visualization tool (e.g. x-rays). 
         [0023]      FIG. 5  shows system architecture  500  of a system that uses the invention to diagnose problems in machines. The system  500  monitors a set of equipment  502  for purposes of maintaining its operation. The equipment  502  comprises machines having parts within their interiors that are monitored by means of visual conduits as discussed above. The equipment  502  is typically expensive to repair because of the troubleshooting required. Each item of equipment  502  interfaces with a network  512  by means of an interface  504 . The interface  504  comprises a module  506  for compressing/transferring images and receiving remote commands. A module  508  comprises camera control interfaces for controlling the location and orientation of the cameras located inside the equipment and a module  510  comprising the internal electronics for controlling the operation of the visual conduits. 
         [0024]    The interface  504  is linked, via a wireless link, with a personal digital assistant  514 ; and via the network  512  to a monitoring center  526 . The monitoring center  526  includes: a remote data analysis module  528 ; a remote data requester  530 ; and a messaging/notification and business process integration module  532 . The remote data analysis module  528  receives data originating from the monitored machine  502  and transmits the data to a corporate repair network  518 . From there, the data can be stored in persistent storage  520 , in proprietary business databases  522 , downloaded to mobile devices  516  such as cell phones, or downloaded directly to the systems of users  524  who monitor the performance of the machines  502 . The remote data requester  530  can be used by a user to request data gathered by sensors monitoring the machines. 
         [0025]    The messaging/notification and business process integration module  532  is used to coordinate the tasks performed using various enterprise business applications that may not have compatible syntax or data structures. Module  532  can comprise software such as IBM&#39;s WebSphere Business Integration™ software or MQ Series. 
         [0026]    What has been shown and discussed is a highly-simplified depiction of a programmable computer apparatus. Those skilled in the art will appreciate that other low-level components and connections are required in any practical application of a computer apparatus. 
         [0027]    Therefore, while there has been described what is presently considered to be the preferred embodiment, it will be understood by those skilled in the art that other modifications can be made within the spirit of the invention.