ENHANCED FLEXIBLE PROCESS OPTIMIZER
First Claim
1. A method for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process, and analyzing waveforms derived from the measured electrical signal parameters to optimize the manufacturing process, the method comprising the steps of:
- (a) acquiring first data related to a first electrical signal parameter indicative of a measure of nominal material removal from a component of manufacture at a given time in a production cycle;
(b) acquiring second data related to a second electrical signal parameter indicative of a measure of power consumed by a material removal tool at any time during the production cycle;
(c) generating first and second waveforms corresponding to the first and second data; and
(d) observing the first and second waveforms on a display device as adjustments are made to optimize the manufacturing process.
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Accused Products
Abstract
The invention describes a flexible process optimizer for recording and analyzing various parameters to improve the efficiency of a production process. The flexible process optimizer acquires and conditions signals from a variety of transducers mounted on a production machine. Through qualitative and quantitative data analysis, specific aspects of the production process which need improvement are identified. The qualitative evaluation looks at the presence, absence, level, rate of change or duration of certain features of the production cycle as revealed by the sensor data. The quantitative evaluation of data involves the computation of certain data attributes. By providing useful data acquisition and data analysis tools, necessary adjustments are made to the required parameters of the production process to provide improved efficiency. The results of the changes are immediately verifiable on the display of the flexible process optimizer.
31 Citations
25 Claims
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1. A method for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process, and analyzing waveforms derived from the measured electrical signal parameters to optimize the manufacturing process, the method comprising the steps of:
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(a) acquiring first data related to a first electrical signal parameter indicative of a measure of nominal material removal from a component of manufacture at a given time in a production cycle; (b) acquiring second data related to a second electrical signal parameter indicative of a measure of power consumed by a material removal tool at any time during the production cycle; (c) generating first and second waveforms corresponding to the first and second data; and (d) observing the first and second waveforms on a display device as adjustments are made to optimize the manufacturing process. - View Dependent Claims (2, 3, 4, 5)
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6. An apparatus for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process performed by a production machine, and analyzing waveforms derived from the measured electrical signal parameters, the apparatus comprising:
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a first sensor module for measuring a first electrical signal indicative of a primary variable in the manufacturing process during a period of time, where the primary variable represents an aspect of the manufacturing process that is controllable by an operator of the production machine; a second sensor module for measuring a second electrical signal indicative of a secondary variable in the manufacturing process during the period of time, where the secondary variable represents a response of the production machine to a change in the primary variable; a processing device in communication with the first and second sensor modules for generating first and second waveforms corresponding to the first and second electrical signals; and a display device in communication with the processing device, the display device for displaying the first and second waveforms to provide information useful in making adjustments to optimize the manufacturing process. - View Dependent Claims (7, 8, 9, 10)
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11. An apparatus for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process performed by a production machine, and analyzing waveforms derived from the measured electrical signal parameters, the apparatus comprising:
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a sensor module for generating a first electrical signal indicative of a parameter of the manufacturing process at a first time; a processing device in communication with the sensor module, the processing device for receiving and processing the first electrical signal to generate a first waveform based thereon; a data storage device for storing the first waveform; the sensor module for generating a second electrical signal indicative of the parameter of the manufacturing process at one or more second times occurring after the first time; the processing device for receiving and processing the second electrical signal to generate a second waveform based thereon; a display device in communication with the processing device, the display device for generating a graphic overlay of the first and second waveforms to allow simultaneous viewing of the first and second waveforms; and an input device in communication with the processing device, the input device for accepting commands from a user to control the processing device to selectively modify the graphic overlay of the first and second waveforms on the display device. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process, and analyzing waveforms derived from the measured electrical signal parameters to optimize the manufacturing process, the method comprising the steps of:
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(a) calibrating at least one sensor module over a first amplitude range; (b) acquiring sensor data related to an electrical signal parameter using the at least one sensor module over the first amplitude range; and (c) generating a real-time waveform corresponding to the sensor data on a display device over a second amplitude range that is less than or greater than the first amplitude range, wherein the second amplitude range is adjustable in real time, and wherein the real-time waveform is generated in a time scale that is adjustable in real time as sensor data is acquired. - View Dependent Claims (21)
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22. A method for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process, and analyzing waveforms derived from the measured electrical signal parameters to optimize the manufacturing process, the method comprising the steps of:
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(a) acquiring sensor data related to one or more electrical signal parameters using at least one sensor module; (b) generating a first waveform corresponding to the sensor data on a display device in a first window, wherein the first waveform has a first time scale and a first amplitude scale, wherein the first amplitude and time scales are adjustable in real time; and (c) generating a second waveform corresponding to the sensor data on the display device in the first window or in a second window that may be positioned on the display device independently of the first window, wherein the second waveform has a second time scale that is different from the first time scale, and a second amplitude scale that is different from the first amplitude scale.
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23. A method for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process performed by a production machine, and analyzing waveforms derived from the measured electrical signal parameters to optimize the manufacturing process, the method comprising the steps of:
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(a) providing one or more sensors attached to the production machine for generating one or more electrical signals indicative of operational characteristics of the production machine; (b) processing the one or more electrical signals to generate operational characteristic data, (c) selecting time and amplitude settings for a display device to display one or more waveforms corresponding to the operational characteristic data, (d) displaying the one or more waveforms on the display device, (e) observing the one or more waveforms on the display device to monitor the manufacturing process, (f) capturing a graphic image of the one or more waveforms displayed on the display device; and (g) storing the graphic image in a storage device for future display.
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24. A method for measuring electrical signal parameters that are indicative of one or more characteristics of a manufacturing process performed by a production machine, and analyzing waveforms derived from the measured electrical signal parameters to optimize the manufacturing process, the method comprising the steps of:
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(a) attaching a plurality of sensors to the production machine for generating sensor signals indicative of operational characteristics of the production machine, the plurality of sensors selected from the group consisting of vibration sensors, position sensors, form sensors, power sensors, fluid characteristic sensors, temperature sensors and pressure sensors; (b) processing the sensor signals to generate sensor data, (c) selecting time and amplitude settings for a display device to display the sensor data, (d) displaying two or more waveforms corresponding to the sensor data from two or more of the plurality of sensor signals simultaneously on the display device, and (e) observing the two or more waveforms on the display device to monitor progress of the production process. - View Dependent Claims (25)
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Specification