System and method for detecting an anomalous condition in a multi-step process
First Claim
1. A system for analyzing an anomalous condition, comprising:
- a process for producing a product, including;
plural subprocesses for performing operations on the product, wherein each subprocess includes at least one actuator for controlling the respective subprocess, wherein each subprocess includes at least one sensor for measuring information pertaining to the status of the respective subprocess, and for generating an output based thereon;
a parameter extractor for, for each of the subprocesses, receiving the output from the at least one sensor, and for generating at least one representative value that is characteristic of a pattern expressed in the output, the parameter extractor thus generating a plurality of representative values for the process as a whole;
a knowledge base for storing data including a plurality of representative values, and also including information which maps the representative values to associated anomalous conditions;
an analyzer for analyzing the plurality of representative values output from the parameter extractor with respect to the data stored in the knowledge base, and for generating a diagnostic result which diagnoses an anomalous condition in the process, and also identifies at least one of the subprocesses which has caused the anomalous condition; and
control logic for using the diagnostic result to affect corrective action to the at least one the subprocesses which has caused the anomalous condition by adjusting at least one actuator that controls the at least one subprocess.
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Abstract
A technique for analyzing an anomalous condition in a process for producing a product is described, where the process includes plural subprocesses for performing operations on the product. The technique includes: (a) for each of the subprocesses, providing sensor output from at least one sensor used to measure information pertaining to the status of the respective subprocess; (b) for each of the subprocesses, extracting at least one representative value that is characteristic of a pattern expressed in the output, thus generating a plurality of representative values for the process as a whole; (c) retrieving data from a knowledge base, the data including a plurality of representative values, and also including information which maps the representative values to associated anomalous conditions; (d) analyzing the plurality of representative values output from the parameter extracting step with respect to the data stored in the knowledge base, and for generating a diagnostic result which diagnoses an anomalous condition in the process, and also identifies at least one of the subprocesses which has caused the anomalous condition; and (e) using the diagnostic result to affect corrective action to the at least one of the subprocesses which has caused the anomalous condition by adjusting at least one actuator that controls the at least one subprocess.
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Citations
20 Claims
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1. A system for analyzing an anomalous condition, comprising:
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a process for producing a product, including;
plural subprocesses for performing operations on the product, wherein each subprocess includes at least one actuator for controlling the respective subprocess, wherein each subprocess includes at least one sensor for measuring information pertaining to the status of the respective subprocess, and for generating an output based thereon;
a parameter extractor for, for each of the subprocesses, receiving the output from the at least one sensor, and for generating at least one representative value that is characteristic of a pattern expressed in the output, the parameter extractor thus generating a plurality of representative values for the process as a whole;
a knowledge base for storing data including a plurality of representative values, and also including information which maps the representative values to associated anomalous conditions;
an analyzer for analyzing the plurality of representative values output from the parameter extractor with respect to the data stored in the knowledge base, and for generating a diagnostic result which diagnoses an anomalous condition in the process, and also identifies at least one of the subprocesses which has caused the anomalous condition; and
control logic for using the diagnostic result to affect corrective action to the at least one the subprocesses which has caused the anomalous condition by adjusting at least one actuator that controls the at least one subprocess. - View Dependent Claims (2, 3, 4, 5)
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6. A system for analyzing an anomalous condition in a process for producing a product, the process including plural subprocesses for performing operations on the product, wherein each subprocess includes at least one actuator for controlling the respective subprocess, and wherein each subprocess includes at least one sensor for measuring information pertaining to the status of the respective subprocess, and for generating an output based thereon, comprising:
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a parameter extractor for, for each of the subprocesses, receiving the output from the at least one sensor, and for generating at least one representative value that is characteristic of a pattern expressed in the output, the parameter extractor thus generating a plurality of representative values for the process as a whole;
a knowledge base for storing data including a plurality of representative values, and also including information which maps the representative values to associated anomalous conditions;
an analyzer for analyzing the plurality of representative values output from the parameter extractor with respect to the data stored in the knowledge base, and for generating a diagnostic result which diagnoses an anomalous condition in the process, and also identifies at least one of the subprocesses which has caused the anomalous condition. - View Dependent Claims (7, 8, 9, 10)
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11. A method for analyzing an anomalous condition in a process for producing a product, the process including plural subprocesses for performing operations on the product, comprising:
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for each of the subprocesses, providing sensor output from at least one sensor used to measure information pertaining to the status of the respective subprocess;
for each of the subprocesses, extracting at least one representative value that is characteristic of a pattern expressed in the output, thus generating a plurality of representative values for the process as a whole;
retrieving data from a knowledge base, the data including a plurality of representative values, and also including information which maps the representative values to associated anomalous conditions;
analyzing the plurality of representative values output from the parameter extracting step with respect to the data stored in the knowledge base, and for generating a diagnostic result which diagnoses an anomalous condition in the process, and also identifies at least one of the subprocesses which has caused the anomalous condition; and
using the diagnostic result to affect corrective action to the at least one of the subprocesses which has caused the anomalous condition by adjusting at least one actuator that controls the at least one subprocess. - View Dependent Claims (12, 13, 14, 15)
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16. A method for analyzing an anomalous condition in a process for producing a product, the process including plural subprocesses for performing operations on the product, where each of the subprocesses provides sensor output from at least one sensor used to measure information pertaining to the status of the respective subprocess, the method comprising the steps of:
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for each of the subprocesses, extracting at least one representative value that is characteristic of a pattern expressed in the output of the at least one sensor, thus generating a plurality of representative values for the process as a whole;
retrieving data from a knowledge base, the data including a plurality of representative values, and also including information which maps the representative values to associated anomalous conditions; and
analyzing the plurality of representative values output from the parameter extracting step with respect to the data stored in the knowledge base, and for generating a diagnostic result which diagnoses an anomalous condition in the process, and also identifies at least one of the subprocesses which has caused the anomalous condition. - View Dependent Claims (17, 18, 19, 20)
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Specification