Control for an industrial process using one or more multidimensional variables

• US 6,853,920 B2
• Filed: 03/09/2001
• Issued: 02/08/2005
• Est. Priority Date: 03/10/2000
• Status: Expired due to Term

• Current Assignee: Smiths Detection Incorporated
• Original Assignee: Smiths Detection Incorporated
• Inventors: Steinthal, Michael Gregory, Hsiung, Chang-Meng B., Vicic, Michael Allen, Zhang, Shou-Hua, Sunshine, Steven A., Roy, Ajoy Kumar, Munoz, Bethsabeth
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US09/802,377
• Publication Number:
  US 20030144746A1
• Time in Patent Office: 1,432 Days
• Field of Search: 700/28, 700 29- 30, 700 47- 49, 702/19, 702/22, 702/33, 702/113, 702/130, 702/183, 702/188, 702/1, 702/189
• US Class Current: 702/1
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/4093 characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine
• CPC Class Codes: G05B 19/41855 by local area network [LAN], network structure
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31265 Control process by combining history and real time data
• CPC Class Codes: G05B 2219/31337 Failure information database
• CPC Class Codes: G05B 2219/31435 Paging support with display board, status monitoring and report compiling
• CPC Class Codes: G05B 2219/31457 Factory remote control, monitoring through internet
• CPC Class Codes: G05B 2219/32129 Select program for specified machine from library, file server
• CPC Class Codes: G05B 2219/32194 Quality prediction
• CPC Class Codes: G05B 2219/32196 Store audit, history of inspection, control and workpiece data into database
• CPC Class Codes: G05B 2219/32201 Build statistical model of past normal proces, compare with actual process
• CPC Class Codes: G05B 2219/32404 Scada supervisory control and data acquisition
• CPC Class Codes: G05B 2219/33209 Protocol, mailbox, email, mail system
• CPC Class Codes: G05B 2219/35095 Features library
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
• CPC Class Codes: G05B 23/0235 based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
• CPC Class Codes: G05B 23/0243 model based detection method, e.g. first-principles knowledge model
• CPC Class Codes: G05B 23/0254 : based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
• CPC Class Codes: G05B 23/0286 : Modifications to the monitored process, e.g. stopping operation or adapting control
• CPC Class Codes: G05B 23/0294 : Optimizing process, e.g. process efficiency, product quality
• CPC Class Codes: Y02A 90/10 : Information and communication technologies [ICT] supporting adaptation to climate change, e.g. for weather forecasting or climate simulation
• CPC Class Codes: Y02P 90/02 : Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 : Management or planning

Abstract

A system for monitoring an industrial process and taking action based on the results of process monitoring. Actions taken may include process control, paging, voicemail, and input for e-enterprise systems. The system includes an input module for receiving a plurality of parameters from a process for manufacture of a substance or object. The system also includes a library module. The library module includes a plurality of computer aided processes. Any one of the computer aided processes is capable of using each of the plurality of parameters to compare at least two of the plurality of parameters against a training set of parameters. The training set of parameters is generally predetermined. The computer aided process is also capable of determining if the at least two of the plurality of parameters are within a predetermined range of the training set of parameters. Additionally, the system includes an output module for outputting a result based upon the training set and the plurality of parameters.

Claims

1. A monitoring system comprising:

a chemical sensor;

a biological sensor;

a radiation sensor;

a network configured to connect said chemical, biological, and radiation sensors;

a layer configured to assimilate sensor data from said chemical, biological, and radiation sensors to form synchronized data; and

a preprocessing module for preprocessing said synchronized data for further processing by a processing manager.

2. The system of claim 1 wherein said chemical sensor is configured to produce a response in the presence of a chemical stimulus selected from the group consisting of a vapor, a gas, a liquid, a solid, an odor or mixtures thereof.

3. The system of claim 2 wherein said chemical sensor is selected from the group consisting of a conducting/nonconducting regions sensor, a SAW sensor, a quartz microbalance sensor, a conductive composite sensor, a chemiresistor, a metal oxide gas sensor, an organic gas sensor, a MOSFET, a piezoelectric device, an infrared sensor, a sintered metal oxide sensor, a Pd-gate MOSFET, a metal FET structure, a electrochemical cell, a conducting polymer sensor, a catalytic gas sensor, an organic semiconducting gas sensor, a solid electrolyte gas sensors, and a piezoelectric quartz crystal sensor.

4. The system of claim 1 wherein said radiation sensor is configured to produce a response in the presence of a stimulus selected from the group consisting of gamma rays, X-rays, ultra-violet rays, visible radiation, infrared, microwaves, and radio waves.

5. The system of claim 1 wherein said chemical, biological, and radiation sensors are wireless sensors configured to communicate with said networking module via a communication mode selected from the group consisting of infrared communications, radiofrequency communications, and combinations thereof.

6. The system of claim 1 wherein said plurality of sensors are non-permanent sensors.

7. The system of claim 1 further comprising a model of a phenomenon, wherein the process manager is configured to apply an application module for applying said model to said synchronized data to generate a descriptor of a state of the phenomenon.

8. The system of claim 7 further comprising a model generation module for generating said model of a phenomenon.

9. The system of claim 8 wherein said model generation module generates a model derived from an event producing at least one of chemical, biological, and radiation stimuli in an environment.

10. The system of claim 8 wherein said model generation module comprises a neural network analysis module.

11. The system of claim 1 wherein the processing manager further comprises:

a module for transmitting a portion of said synchronized data to a data interpretation system.

12. The system of claim 1 wherein the processing manager further comprises:

a diagnostic module.

13. The system of claim 12 wherein said diagnostic module comprises modules for identifying an event producing at least one of a chemical, biological, and radiation stimulus.

14. The system of claim 1 wherein the processing manager further comprises:

modules for providing a notification regarding an occurrence of an event.

15. The system of claim 1 wherein the processing manager further comprises:

modules for initiating follow-on actions.

16. The system of claim 15 wherein said follow-on actions include correction means responsive to an event.

17. The system of claim 1 wherein said network further comprises:

a short-range transceiver node, configured to be connected with said chemical, biological, and radiation sensors;

a local hub, connected with said short range transceiver node;

and a long-range transceiver hub connected with a pre-existing monitoring system, wherein said long-range transceiver hub is configured to exchange data with said local hub.