Reuse of manufacturing process design models as part of a diagnostic system

• US 20060069541A1
• Filed: 09/30/2004
• Published: 03/30/2006
• Est. Priority Date: 09/30/2004
• Status: Active Grant

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Coburn, James D., Walacavage, Joseph G.
• Granted Patent: US 7,716,014 B2
• Time in Patent Office: Days
• US Class Current: 703/22
• CPC Class Codes: G05B 19/4188 characterised by CIM planning or realisation
• CPC Class Codes: G05B 2219/31449 Monitor workflow, to optimize business, industrial processes
• CPC Class Codes: G05B 2219/32083 Alternative, variant operation planning, revision specification of product
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method and apparatus that includes determining differences between a process model and an actual process are used as a diagnostic system for the actual process. The process model includes elements from a design process to provide a “known good” condition for evaluating the differences. Initial input states to the process model are the initial input states to the actual process. Output information correlated to states in the actual process is provided by controls, such as programmable logic controllers, that manage the actual process.

Claims

1. A method comprising:

acquiring output from a process model having elements reused from a design process;

obtaining output information generated from an actual process; and

determining a difference between the process model and the actual process using the output information and the output from the process model to diagnose the actual process, wherein initial input states of the actual process are used as initial inputs to the process model.

2. The method of claim 1, wherein obtaining output information includes obtaining a current status of elements operating in the actual process.

3. The method of claim 1, wherein acquiring output includes acquiring an expected current status of elements operating in the actual process.

4. The method of claim 1, wherein determining a difference between the process model and the actual process includes comparing the output from the process model with the output information.

5. The method of claim 1, wherein determining a difference between the process model and the actual process includes comparing an input image table from the actual process with an input image table from the process model, both input image tables correlated to common initial input states.

6. The method of claim 1, wherein the method further includes providing the process model with process logic verified in the design process as the elements reused from the design process.

7. The method of claim 1, wherein obtaining output information generated from an actual process includes obtaining the output information from one or more controllers.

8. The method of claim 1, wherein the method further includes scanning element input states into the process model at a scan rate.

9. The method of claim 1, wherein the method further includes scanning element input states into the process model at a rate such that aperiodic events are captured.

10. The method of claim 1, wherein the method further includes announcing the difference between the process model and the actual process.

11. The method of claim 1, wherein the method further includes logging information associated with the difference between the process model and the actual process.

12. The method of claim 1, wherein the method further includes analyzing the difference between the process model and the actual process.

13. The method of claim 1, wherein the method further includes reinitiating the design process based on analyzing the difference between the process model and the actual process to evolve the process model.

14. The method of claim 1, wherein providing a process model includes integrating logic from a plurality of design processes.

15. A computer-readable medium having computer-executable instructions for performing a method comprising:

acquiring output from a process model having elements reused from a design process;

obtaining output information of an actual process; and

determining a difference between the process model and the actual process using the output information and the output from the process model to diagnose the actual process, wherein initial input states of the actual process are used as initial inputs to the process model.

16. The computer-readable medium of claim 15, wherein the output information of the actual process includes a current status of elements operating in the actual process and the output from the process model includes an expected current status of elements operating in the actual process.

17. The computer-readable medium of claim 15, wherein the method further includes scanning element input states into the process model at a scan rate.

18. The computer-readable medium of claim 15, the method further includes scanning element input states into the process model at a rate such that aperiodic events are captured.

19. The computer-readable medium of claim 15, wherein the method further includes announcing the difference between the process model and the actual process.

20. The computer-readable medium of claim 15, wherein the method further includes logging information associated with the difference between the process model and the actual process.

21. The computer-readable medium of claim 15, wherein the method further includes analyzing the difference between the process model and the actual process.

22. The computer-readable medium of claim 15, wherein the method further includes reinitiating the design process based on analyzing the difference between the process model and the actual process.

23. The computer-readable medium of claim 15, wherein determining a difference between the process model and the actual process includes comparing an input image table from the actual process with an input image table from the process model, both input image tables correlated to common initial input states.

24. The computer-readable medium of claim 15, wherein the process model includes logic integrated from a plurality of design processes.

25. An apparatus comprising:

a process model adapted to virtually perform logical tasks based on elements reused from a design process and provide outputs; and

a difference engine to compare the outputs from the process model with output information correlated to an actual process to diagnose the actual process, wherein initial input states to the actual process are used as initial inputs to the process model.

26. The apparatus of claim 25, wherein the output information correlated to the actual process includes a current status of elements operating in the actual process and the outputs from the process model include an expected current status of elements operating in the actual process.

27. The apparatus of claim 25, wherein at least a portion of the output information correlated to an actual process is provided from a controller that manages a portion of the actual process.

28. The apparatus of claim 25, wherein the process model includes hardware logic to provide the outputs in response to determining expected element input states.

29. The apparatus of claim 25, wherein the process model includes software to provide the outputs in response to determining expected element input states.

30. The apparatus of claim 25, wherein the apparatus includes an annunciator to signal an occurrence of the difference between the process model and the actual process.

31. The apparatus of claim 25, wherein the apparatus includes a log to collect information associated with the difference between the process model and the actual process.

32. The apparatus of claim 25, wherein the apparatus includes an analysis unit having historical information regarding the actual process.

33. The apparatus of claim 25, wherein the process model includes a plurality of component process models in a one-to-one relationship with a plurality of controllers that manage the actual process, the plurality of component process models adapted to diagnose the actual process as an integration of a plurality of component actual processes.

34. A system comprising:

a process model adapted to virtually perform logical tasks based on elements reused from a design process and provide outputs;

a controller adapted to regulate tasks of an actual process, the controller configured to provide output information correlated to the actual process; and

a difference engine to compare the outputs from the process model with output information from the controller to determine a difference between the process model and an actual process to diagnose the actual process, wherein initial input states to the controller are used as initial inputs to the process model.

35. The system of claim 34, wherein the output information correlated to the actual process includes a current status of elements operating in the actual process and the outputs from the process model include an expected current status of elements operating in the actual process.

36. The system of claim 34, wherein the apparatus includes an annunciator to signal an occurrence of the difference between the process model and the actual process.

37. The system of claim 34, wherein the apparatus includes a log to collect information associated with the difference between the process model and the actual process.

38. The system of claim 34, wherein the apparatus includes an analysis unit having historical information regarding the actual process.

39. The system of claim 34, wherein the process model includes a plurality of component process models in a one-to-one relationship with a plurality of controllers that manage the actual process, the plurality of component process models adapted to diagnose the actual process as an integration of a plurality of component actual processes.

40. The system of claim 34, wherein the system is a manufacturing plant having a number of manufacturing lines.