Machine management systems and monitoring methods

• US 6,496,751 B1
• Filed: 12/16/1999
• Issued: 12/17/2002
• Est. Priority Date: 12/16/1999
• Status: Expired due to Fees

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Salvo, Joseph James, Mackenzie, Patricia Denise, Morelli, Thomas Anthony II
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): RODRIGUEZ, PAUL L
• Application Number:
  US09/464,872
• Time in Patent Office: 1,097 Days
• Field of Search: 700/196, 700/197, 700/202-205, 700/180, 700/96, 700/108, 700/109, 700/169, 700/159, 700/174, 702/188
• US Class Current: 700/196
• CPC Class Codes: G05B 21/02 electric
• CPC Class Codes: G05B 2219/31104 Remote configuration of parameters of controlled devices
• CPC Class Codes: G05B 2219/34038 Web, http, ftp, internet, intranet server

Abstract

A process management system for at least one of monitoring and controlling operation of a machine comprises at least one sensor assembly capable of being disposed on the machine for at least one of sensing, monitoring, and transmitting machine process variables of the machine, the at least one sensor assembly is capable of transmitting signals concerning the machine process variables; at least one machine operator control unit that is capable of receiving signals transmitted from the at least one sensor assembly, the at least one machine operator control unit being capable of generating information concerning machine process variables; at least one process management system control unit that is capable of being connected to the at least one machine operator control unit; at least one communications link that interconnects the at least one sensor assembly on the machine, the at least one machine operator control unit, and the at least one process management system control unit, each communications link capable of enabling the at least one process management system control unit to obtain the information concerning machine process variables. At least one of the process management system control unit and the machine operator control unit is capable of analyzing and evaluating machine process variables to control the operation of the machine. The invention also sets forth a method of monitoring.

Claims

1. A process management system for at least one of monitoring operation of a machine, controlling operation of the machine, and for analyzing and evaluating machine process variables, the process management system comprising:

at least one sensor assembly that is capable of being disposed on the machine for at least one of sensing, monitoring, and transmitting machine process variables of the machine, the at least one sensor assembly being capable of transmitting signals concerning the machine process variables;

at least one machine operator control unit that is capable of receiving signals transmitted from the at least one sensor assembly, the at least one machine operator control unit being capable of generating information concerning machine process variables;

at least one process management system control unit that is capable of being connected to the at least one machine operator control unit; and

at least one communications link that interconnects the at least one sensor assembly on the machine, the at least one machine operator control unit, and the at least one process management system control unit, each communications link capable of enabling the at least one process management system control unit to obtain the information concerning machine process variables;

wherein at least one of the process management system control unit and the machine operator control unit is capable of analyzing and evaluating machine process variables to control the operation of the machine, and wherein operation of the machine is enhanced by users being able to access the analyzed and evaluated machine process variables and use the analyzed and evaluated machine process variables for at least one of;

manufacturing planning, process planning, predicting process planning, and process variable planning decision making.

2. A process management system according to claim 1, wherein the at least one communications link comprises a network connection.

3. A process management system according to claim 1, wherein the communications link comprises an Internet connection.

4. A process management system according to claim 1, wherein the communications link comprises at least one of:

a phone modem connection, a radio communication connection, a network communication connection, a wireless communication system connections, a cellular communication connection, a satellite communication connection, a web connection, an Internet connection, and combinations thereof.

5. A process management system according to claim 1, wherein at least one of the process management system control unit and the machine operator control unit comprises means for statistically analyzing and evaluating machine process variables.

6. A process management system according to claim 1, wherein the at least one process management system control unit comprises a computer.

7. A process management system according to claim 1, wherein the at least one machine operator control unit comprises a computer.

8. A process management system according to claim 1, wherein the process management system provides real-time machine process variables to at least one of the process management system control unit and the machine operator control unit.

9. A process management system according to claim 1, wherein the process management system provides historical machine process variable characteristics.

10. A process management system according to claim 1, wherein the information concerning machine process variables is automatically generated.

11. A process management system according to claim 10, wherein the information concerning machine process variables is automatically generated at regular intervals.

12. A process management system according to claim 1, wherein the machine process variable information comprises at least one of real-time machine process variable information, historical machine process variable information, and a combination of real-time and historical machine process variable information.

13. A process management system according to claim 1, further comprising at least one of a raw material data source unit, a raw material vendor source unit, and a market information source unit, at least one of the raw material data source unit, the raw material vendor source unit, and the market information source unit being connected to at least one of the process management system control unit and the machine operator control unit to transmit raw material information, raw material vendor information, and market information thereto.

14. A process management system according to claim 1, the process management system further comprising a web site that is capable of displaying the machine process variable information from at least one of the process management system control unit and the machine operator control unit.

15. A process management system according to claim 1, wherein at least one of the process management system control unit and the machine operator control unit is capable of data acquisition, data mining, and data analysis of machine process variables.

16. A process management system according to claim 1, wherein at least one of the process management system control unit and the machine operator control unit is capable of developing and modifying transfer functions.

17. A process management system according to claim 16, wherein the transfer functions can be developed and updated through evaluation and analysis of at least one of machine process variables, product analysis information, and critical to quality (CTQ) variables.

18. A process management system according to claim 16, wherein the transfer functions can be developed and modified through design-of-experiments analysis.

19. A process management system according to claim 16, wherein at least one of the process management system control unit and the machine operator control unit is capable of applying quality-related analytical tools to the machine process variables.

20. A process management system according to claim 1, wherein each sensor assembly is disposed on a component of the machine to sense, monitor, and transmit machine process variables of the component, wherein each sensor assembly can control operation of the respective component to change machine process variables.

21. A process management system according to claim 20, wherein each component is designed to operate in a machine process variable range, the sensor assembly transmits machine process variables to at least one of the process management system control unit and the machine operator control unit, and at least one of the process management system control unit and the machine operator control unit evaluates and analyzes the machine process variables from the sensor assembly and determines if the machine process variables are within the respective machine process variable range.

22. A process management system according to claim 21, wherein if at least one of the process management system and the machine operator control unit evaluates and analyzes the machine process variables from the at least one sensor assembly and determines that the machine process variables are within the machine process variable range, machine operation is continued, and if at least one of the process management system control unit and the machine operator control unit evaluates and analyzes the machine process variables from the sensor assembly and determines that the machine process variables are not within the machine process variable range, at least one of the process management system control unit and the machine operator control unit communicates with the sensor assembly to control the machine process variables of the machine component so the machine process variables are returned to within the machine process variable range.

23. A process management system according to claim 1, wherein the machine comprises an extruder.

24. A process management system according to claim 23, wherein the extruder comprises a foam-forming unit and a skin-forming unit, each of the foam-forming unit and the skin-forming unit comprising a respective sensor assembly.

25. A process management system according to claim 23, wherein the extruder comprises at least one of a receiving chamber, a motive device that moves material into the extruder, units that apply heat to material in the extruder, units that apply or develop pressure on the material in the extruder, a joining chamber that forms an intermediate extruded product material, general-shaping chambers that extrude an intermediate product, a final shaper unit that shapes or cools the extruded product, a final motive device that moves the extruded product from the extruder, and a cutting device for separating the extruded product into desired lengths,

wherein each of the at least one receiving chamber, the motive device that moves material into the extruder, the units that apply heat to material in the extruder, the units that apply or develop pressure on the material in the extruder, the joining chamber that forms an intermediate extruder product material, the general-shaping chambers that extrude an intermediate product, the final shaper unit that shapes or cools the extruded product, the final motive device that moves the extruded product from the extruder, and the cutting device for separating the extruded product into desired lengths comprises a respective sensor assembly.

26. An extruder apparatus connected to the process management system of claim 1.

27. A process management system for at least one of monitoring operation of a machine, controlling operation of the machine, and for analyzing and evaluating machine process variables, the process management system comprising:

sensor means disposed on the machine for at least one of sensing, monitoring, and transmitting machine process variables of the machine, the sensor means being capable of transmitting signals concerning the machine process variables;

machine operator control means for receiving signals transmitted from the sensor means, the machine operator control means being capable of generating information concerning machine process variables;

process management system control means for being connected to the machine operator control means; and

communications link means for interconnecting the sensor means on the machine, the machine operator control means, and the process management system control means, each communications link means enabling the process management system control means to obtain the information concerning machine process variables;

wherein at least one of the process management system control means and the machine operator control means is capable of analyzing and evaluating machine process variables to control the operation of the machine, and wherein operation of the machine is enhanced by users being able to access the analyzed and evaluated machine process variable and use the analyzed and evaluated machine process variables for at least one of;

manufacturing planning, process planning, predicting process planning, and process variable planning decision making.

28. A process management system according to claim 27, wherein the communications link means comprises an Internet connection.

29. A process management system according to claim 27, wherein the communications link means comprises at least one of:

a phone modem connection, radio communication connection, a network communication connection, a wireless communication system connections, a cellular communication connection, a satellite communication connection, a web connection, an Internet connection, and combinations thereof.

30. A process management system according to claim 27, wherein the process management system control means comprises a computer.

31. A process management system according to claim 27, wherein the machine operator control means comprises a computer.

32. A process management system according to claim 27, wherein the process management system provides real-time machine process variables to at least one of the process management system control means and the machine operator control means.

33. A process management system according to claim 27, wherein the process management system provides historical machine process variable characteristics.

34. A process management system according to claim 27, wherein the information concerning machine process variables is automatically generated.

35. A process management system according to claim 34, wherein the information concerning machine process variables is automatically generated at regular intervals.

36. A process management system according to claim 27, wherein the machine process variable information comprises at least one of real-time machine process variable information, historical machine process variable information, and a combination of real-time and historical machine process variable information.

37. A process management system according to claim 27, further comprising at least one of a raw material data source unit, a raw material vendor source unit, and a market information source unit, at least one of the raw material data source unit, the raw material vendor source unit, and the market information source unit being connected to at least one of the process management system control means and the machine operator control means to transmit raw material information, raw material vendor information, and market information thereto.

38. A process management system according to claim 27, the process management system further comprising a web site means for displaying the machine process variable information from at least one of the process management system control means and the machine operator control means.

39. A process management system according to claim 27, wherein at least one of the process management system control means and the machine operator control means is capable of data acquisition, data mining, and data analysis of machine process variables.

40. A process management system according to claim 27, wherein at least one of the process management system control means and the machine operator control means is capable of developing and modifying transfer functions.

41. A process management system according to claim 40, wherein the transfer functions can be developed and updated through evaluation and analysis of at least one of machine process variables, product analysis information, and critical to quality (CTQ) variables.

42. A process management system according to claim 40, wherein the transfer functions can be developed and modified through design-of-experiments analysis.

43. A process management system according to claim 27, wherein at least one of the process management system control means and the machine control means is capable of applying quality-related analytical tools to the machine process variables.

44. A process management system according to claim 27, wherein each sensor means is disposed on a component of the machine to sense, monitor, and transmit machine process variables of the component, wherein each sensor means can control operation of the respective component.

45. A process management system according to claim 44, wherein each component is designed to operate in a machine process variable range, the sensor means transmits machine process variables to at least one of the process management system control means and the machine operator control means, and at least one of the process management system control means and the machine operator control means evaluates and analyzes the machine process variables from the sensor means and determines if the machine process variables are within the machine process variable range.

46. A process management system according to claim 45, wherein if at least one of the process management system control means and the machine operator control means evaluates and analyzes the machine process variables from the sensor means and determines that the machine process variables are within the machine process variable range, machine operation is continued, and if at least one of the process management system control means and the machine operator control means evaluates and analyzes the machine process variables from the sensor means and determines that the machine process variables are not within the machine process variable range, at least one of the process management system control means and the machine operator control unit means communicates with the sensor means to control the machine process variables of the machine component so the machine process variables are returned to within the machine process variable range.

47. A process management system according to claim 27, wherein the machine comprises an extruder.

48. A process management system according to claim 47, wherein the extruder comprises a foam-forming unit and a skin-forming unit, each of the foam-forming unit and the skin-forming unit comprising a respective sensor assembly.

49. A process management system according to claim 47, wherein the extruder comprises at least one of a receiving chamber, a motive device that moves material into the extruder, units that apply heat to material in the extruder, units that apply or develop pressure on the material in the extruder, a joining chamber that forms an intermediate extruder product material, general-shaping chambers that extrude an intermediate product, a final shaper unit that shapes or cools the extruded product, a final motive device that moves the extruded product from the extruder, and a cutting device for separating the extruded product into desired lengths,

wherein each of the at least one receiving chamber, the motive device that moves material in the extruder, the units that apply heat to material in the extruder, the units that apply or develop pressure on the material in the extruder, the joining chamber that forms an intermediate extruder product material, the general-shaping chambers that extrude an intermediate product, the final shaper unit that shapes or cools the extruded product, the final motive device that moves the extruded product from the extruder, and the cutting device for separating the extruded product into desired lengths comprises a respective sensor assembly.

50. An extruder apparatus connected to the process management system of claim 27.

51. A process management method for at least one of monitoring operation of a machine, controlling operation of the machine, and for analyzing and evaluating machine process variables, the process management method comprising:

disposing at least one sensor assembly on the machine;

sensing, monitoring, and transmitting machine process variables of the machine;

connecting each sensor assembly to a process management system control unit and a machine operator control unit;

receiving signals transmitted from the at least one sensor assembly by at least one of the process management system control unit and the machine operator control unit;

generating information concerning machine process variables by at least one of the process management system control unit and the machine operator control unit; and

analyzing and evaluating machine process variables by at least one of the process management system control unit and the machine operator control unit to control the operation of the machine, wherein operation of the machine is enhanced by users being able to access the analyzed and evaluated machine process variables and use the analyzed and evaluated machine process variables for at least one of;

manufacturing planning, process planning, predicting process planning, and process variable planning decision making.

52. A process management method according to claim 51, wherein the step of connecting comprises establishing a network connection.

53. A process management method according to claim 51, wherein the step of connecting comprises establishing an Internet connection.

54. A process management method according to claim 51, wherein the step of connecting comprises establishing a communications link over at least one of:

a phone modem connection, radio communication connection, a network communication connection, a wireless communication system connections, a cellular communication connection, a satellite communication connection, a web connection, an Internet connection, and combinations thereof.

55. A process management method according to claim 51, wherein the step of analyzing and evaluating the machine process variables comprises statistically analyzing and evaluating the machine process variables.

56. A process management method according to claim 51, wherein the process management method provides real-time machine process variables.

57. A process management method according to claim 51, wherein the process management method provides historical machine process variable characteristics.

58. A process management method according to claim 51, wherein the information concerning machine process variables is automatically generated.

59. A process management method according to claim 51, wherein the step of generating information concerning machine process variables comprises automatically generating the information concerning machine process variables at regular intervals.

60. A process management method according to claim 51, wherein the machine process variable information comprises at least one of real-time machine process variable information, historical machine process variable information, and a combination of real-time and historical machine process variable information.

61. A process management method according to claim 51, further providing the process management system control unit and the machine operator control unit with at least one of a raw material data source unit, a raw material vendor source unit, and a market information source unit, at least one of the raw material data source unit, the raw material vendor source unit, and the market information source unit being connected to at least one of the process management system control unit and the machine operator control unit to transmit raw material information, raw material vendor information, and market information thereto.

62. A process management method according to claim 51, further comprising the step of displaying machine process variable information on a web site.

63. A process management method according to claim 51, wherein the step of analyzing and evaluating the machine process variables comprises at least one of data acquisition, data mining, and data analysis.

64. A process management method according to claim 51, wherein the step of analyzing and evaluating the machine process variables further comprises developing and modifying transfer functions.

65. A process management method according to claim 64, wherein the step of developing and modifying transfer functions comprises developing and updating transfer functions through evaluation and analysis of at least one of machine process variables, product analysis information, and critical to quality (CTQ) variables.

66. A process management method according to claim 64, wherein the step of developing and modifying transfer functions comprises developing and modifying the transfer functions through design-of-experiments analysis.

67. A process management method according to claim 51, wherein the step of developing and modifying transfer functions comprises applying quality-related analytical tools to the machine process variables.

68. A process management method according to claim 51, further comprising the step of controlling operation of a component of the machine upon which a sensor assembly is disposed, the step of controlling comprising sensing, monitoring, and transmitting machine process variables from the sensor assembly, wherein each sensor assembly can control operation of the respective component to change machine process variables.

69. A process management method according to claim 68, wherein each component is designed to operate in a machine process variable range, and the sensor assembly transmits machine process variables to at least one of the process management system control unit and the machine operator control unit, and at least one of the process management system control unit and the machine operator control unit evaluates and analyzes the machine process variables from the sensor assembly and determines if the machine process variables are within the machine process variable range.

70. A process management method according to claim 51, wherein if at least one of the process management system control unit and the machine operator control unit evaluates and analyzes the machine process variables from the sensor assembly and determines that the machine process variables are within the machine process variable range, machine operation is continued, and if at least one of the process management system control unit and the machine operator control unit evaluates and analyzes the machine process variables from the sensor assembly and determines that the machine process variables are not within the machine process variable range, at least one of the process management system control unit and the machine operator control unit communicates with the sensor assembly to control the machine process variables of the machine component so the machine process variables are returned to within the machine process variable range.

71. A process management method according to claim 51, wherein the machine comprises an extruder.

72. A process management method according to claim 71, wherein the extruder comprises a foam-forming unit and a skin-forming unit, each of the foam-forming unit and the skin-forming unit comprising a respective sensor assembly.

73. A process management method according to claim 72, wherein the extruder comprises at least one of a receiving chamber, a motive device that moves material into the extruder, units that apply heat to material in the extruder, units that apply or develop pressure on the material in the extruder, a joining chamber that forms an intermediate extruder product material, general-shaping chambers that extrude an intermediate product, a final shaper unit that shapes or cools the extruded product, a final motive device that moves the extruded product from the extruder, and a cutting device for separating the extruded product into desired lengths,

wherein each of the at least one receiving chamber, the motive device that moves material in the extruder, the units that apply heat to material in the extruder, the units that apply or develop pressure on the material in the extruder, the joining chamber that forms an intermediate extruder product material, the general-shaping chambers that extrude an intermediate product, the final shaper unit that shapes or cools the extruded product, the final motive device that moves the extruded product from the extruder, and the cutting device for separating the extruded product into desired lengths comprises a respective sensor assembly.

74. A method for doing business comprising the process management method of claim 51.

75. A business method for providing a business service comprising the process management method of claim 51.