Computerized voc and solvent usage warning system

• US 6,804,567 B2
• Filed: 08/23/2001
• Issued: 10/12/2004
• Est. Priority Date: 11/10/1997
• Status: Expired due to Term

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Corporation (BASF SE)
• Inventors: Shadow, Gregory S., Datsko, Aimee R., Kerkau, Melissa S., Lamberty, Paul E.
• Primary Examiner(s): Knight, Anthony
• Assistant Examiner(s): Hartman, Jr., Ronald D
• Application Number:
  US09/938,396
• Publication Number:
  US 20020077716A1
• Time in Patent Office: 1,146 Days
• Field of Search: 700/95, 700/96, 700/97, 700/117, 401/29, 401/44
• US Class Current: 700/97
• CPC Class Codes: B05B 12/00 Arrangements for controlling delivery; Arrangements for controlling the spray area
• CPC Class Codes: G05B 19/406 characterised by monitoring or safety G05B19/19 takes precedence
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31206 Exchange of parameters, data, programs between two station, station and central or host or remote
• CPC Class Codes: G05B 2219/31282 Data acquisition, BDE MDE
• CPC Class Codes: G05B 2219/31483 Verify monitored data if valid or not by comparing with reference value
• CPC Class Codes: G05B 2219/32074 History of operation of each machine
• CPC Class Codes: G05B 2219/32348 Process reengineering, rethink manufacturing process, continuous improve
• CPC Class Codes: G05B 2219/32351 Visual, graphical animation of process
• CPC Class Codes: G05B 2219/32368 Quality control
• CPC Class Codes: G05B 2219/33209 Protocol, mailbox, email, mail system
• CPC Class Codes: G05B 2219/34039 Access central database through internet
• CPC Class Codes: G05B 2219/45013 Spraying, coating, painting
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A computer-implemented apparatus is provided for coordinating paint-related process steps at a paint-application facility. The paint-related process steps include at least one of: data collecting, calculating, evaluating and reporting volatile organic content of paint and actual and projected paint and solvent usage from a painting process and solvent and volatile organic emission regulation data.

Claims

1. A computer-implemented apparatus for coordinating paint-related process steps of at least one paint-application facility, said paint-related process steps comprising at least one of data collecting, calculating, evaluating and reporting at least one of volatile organic content of paint, actual paint usage, projected paint usage, projected solvent usage from a painting process, solvent emission data, and volatile organic emission data, said apparatus comprising:

a process control data structure for collecting paint process control data selected from the group consisting of paint related characteristics, solvent additions, projected paint usage, emissions regulation data and combinations thereof, and for calculating total projected volatile organic emissions, total projected volatilized emissions of specific solvents and comparing said emissions to regulatory limits for said emissions,

a paint application facility database for collecting and storing paint characteristic data, solvent additions, paint usage data and emission regulation data;

a calculation means attached to said database (a) for calculating total projected volatile organic emissions, total projected volatized emissions of specific solvents and for comparing said emissions to regulatory allowed emission limits;

at least one data display connected to said database and calculation means for receiving and displaying reports based on calculations provided by said calculation means; and

a warning device activated by computer software and connected to said database and calculation means, for displaying a warning response generated by computer software communicated from electronic media connected to at least one of said database or data display.

2. The apparatus of claim 1 wherein said database further collects and stores paint material data and vehicle assembly plant data.

3. The apparatus of claim 1 wherein said data display provides volatile organic emissions reports and combinations thereof.

4. The apparatus of claim 1 wherein said data display provides a computer software activated data display warning message related to at least one of volatile organic emissions and regulatory limits for said emissions.

5. The apparatus of claim 1 wherein said warning device is an electronic means selected from the group consisting of web-based communication systems, electronic mail, web enabled pager devices, web enabled cellular telephonic devices, non-web enabled telephonic devices, and non-web enabled pager devices and combinations thereof.

6. The apparatus of claim 1 wherein the acquired paint characteristic data includes paint material constants and paint parameters.

7. The apparatus of claim 1 wherein the calculation means comprises a simplex calculator for constraining the permissible range of emissions from at least one painting facility within allowable regulatory ranges.

8. The apparatus of claim 1 further comprising:

a plurality of data displays for remotely receiving and displaying reports based on calculations provided by calculation means.

9. The apparatus of claim 8 further comprising:

a security database for providing security authorizations with respect to said plurality of data displays for remotely receiving and displaying said reports.

10. The apparatus of claim 1 further comprising means for connection to a centralized paint information and application system.

11. A method of determining volatile organic content emissions in a paint application facility and consequently performing a warning operation based on a determination of volatile organic content emissions, comprising

(a) providing the paint application facility with a computer-implemented apparatus according to claim 1;

(b) communicating and storing to a paint application facility database and to a calculation means, data selected from the group consisting of paint material data, paint application data, paint related characteristics, amount of solvent additions, solvent emission data, projected paint usage and emissions regulation data and combinations thereof,

(c) calculating the data received from the database with the calculation means;

(d)displaying the data via a computer based data display;

(e) coordinating the paint material data, the paint application data, the solvent emission data and the emissions regulations data;

(f) activating a warning via computer software, connected to said database and calculation means, where said warning is activated when coordinated volatile organic emission data and volatile organic emission regulatory limit data indicate regulatory solvent limits are or will be exceeded.

12. The method of claim 11 wherein said data is acquired from paint characteristic data and paint application facility data.

13. The method of claim 11 wherein a solvent limits report or volatile organic emissions report is displayed via a computer data display.

14. The method of claim 11 wherein a warning message activated by data from volatile organic emissions data and volatile organic emissions regulation data for said emissions is displayed via said computer data display.

15. The method of claim 11 wherein said warning is displayed via electronic means other than a computer data display.

16. The method of claim 15 wherein said warning is displayed via an electronic device selected from the group consisting of web-based communication systems, electronic mail, web enabled pager devices, web enabled cellular telephonic devices, non-web enabled telephonic devices, non-web enabled pager devices and combinations thereof.

17. The method of claim 11 wherein said step of communicating and storing the paint characteristic data includes data selected from the group consisting of paint constants, paint parameters and paint application data.

18. The method of claim 11 wherein the calculation step is performed by a simplex calculator.

19. The method of claim 18 wherein the simplex calculator constrains the permissible range of emissions from a painting facility within allowable regulatory ranges.