System and method for processing data relating to conditions in a manufacturing process

• US 6,862,486 B2
• Filed: 03/04/2003
• Issued: 03/01/2005
• Est. Priority Date: 03/04/2003
• Status: Active Grant

• Current Assignee: Aptean, Inc. (Aptean Superior Holdings, Inc.)
• Original Assignee: Activplant Corp. (Aptean Superior Holdings, Inc.)
• Inventors: Cocco, Dennis Pio, Cui, Jianrong, Cocco, Victoria Louisa, Sehovic, Samir
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): SHECHTMAN, SEAN P
• Application Number:
  US10/377,731
• Publication Number:
  US 20040176864A1
• Time in Patent Office: 728 Days
• Field of Search: 700/12, 700/14, 700/15, 700/16, 700/27, 700/90, 700/95, 700/96, 700/100, 700/101, 700/108, 700/305, 707/100
• US Class Current: 700/95
• CPC Class Codes: G05B 19/4183 characterised by data acquisition, e.g. workpiece identification
• CPC Class Codes: G05B 2219/31323 Database for CIM
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The invention provides a system and method for processing data relating to conditions in a manufacturing process. The system and method provide a time based relationship between data items of the data collected in a manufacturing process. More abstract and different data models may be defined enabling application of these data models in different systems without having to define the new models from the basic data items for each system. The system and method provide an identifier data type that allows association of a meaningful identifier with a time interval and a source. The identifier is associated with other data items through the relationship of time interval and source. Values of the identifier are dynamically defined and relate to either identity of an article being processed during the time interval or a status of the manufacturing process during the time interval.

Claims

1. A method of processing data relating to conditions in a manufacturing process, said data being relateable to one of a plurality of data types, said method comprising:

relating a first data item of said data to a first data type of said plurality of data types;

associating said first data item with a first time marker;

associating said first data item with a source in said manufacturing process;

associating said first data item with an identifier, said value of said identifier being capable of being one of a set of a plurality values, each said value in said set relating to a condition of said conditions, said set being expandable during operation of said manufacturing process;

relating a second data item of said data to a second data type of said plurality of data types;

associating a second data item with a second time marker;

associating said second data item with a source in said manufacturing process; and

upon a receiving a request, associating said value of said identifier associated with said first data item with said second data item if;

said first time marker associated with said first data item corresponds to said second time marker associated with said second data item; and

said source associated with said first data item corresponds to said source associated with said second data item,

wherein said value of said identifier indicates one of;

a) identity of an article processed during a first time interval indicated by said first time marker; and

b) a status of said manufacturing process during said first time interval indicated by said first time marker.

2. The method as claimed in claim 1, wherein, when said value of said identifier indicates said article processed during said first time interval, said article is one of:

a1) a part processed;

a2) a batch of parts processed; and

a3) a model processed.

3. The method as claimed in claim 1, wherein, when said value of said identifier indicates status of said manufacturing process during said first time interval, said status is a shift identifier identifying a particular work shift in which parts are processed.

4. The method as claimed in claim 1, wherein said first time marker indicates a start time for said first time interval.

5. The method as claimed in claim 4, wherein said first time marker further indicates an end time for said first time interval, said start time and said end time indicating a duration of said first time interval.

6. The method as claimed in claim 5, wherein said second time marker indicates one of a point in time and a second time interval.

7. The method as claimed in claim 6, wherein said second time marker is said point in time and said first time marker corresponds to said second time marker if said point in time occurs within said first time interval.

8. The method as claimed in claim 6, wherein said second time marker is said second time interval and said first time marker corresponds to said second time marker if at least a portion of said second time interval occurs within said first time interval.

9. The method as claimed in claim 6, wherein said second data type is one of:

a) an accumulator data type, said second time marker is said second time interval and said method further comprises the step of associating said second data item with an accumulator value, said accumulator value relating to a count for said second time interval;

b) an event data type, said second time marker is said point in time and said method further comprises the step of associating said second data item with an event value, said event value relating to a process variable for said point in time; and

c) an incident data type, said second time marker is said second time interval and said method further comprises the step of associating said second data item with an incident value, said incident value relating to an incident occurring in said second time interval.

10. The method as claimed in claim 9, wherein said second data type is an incident data type and said method further comprises the step of associating a priority level to said incident value to prioritize said second data item against another data item of said second data type associated with data relating to a condition in said manufacturing process.

11. The method as claimed in claim 6, wherein said source is one of a machine, a portion of a machine and a group of machines in said manufacturing process.

12. The method as claimed in claim 11, said method further comprising the step of storing said first data item and said second data item in a database prior to requesting said association between said value of said identifier and said second data item.

13. The method as claimed in claim 12, wherein said first data item and said second data item are stored as records in tables in said database.

14. The method as claimed in claim 13, wherein said first data type further provides a link to another data type of said plurality of data types to allow data in said another data type to be associated with data in said first data type.

15. The method as claimed in claim 14, said method further comprising the step of, in response to said request, accessing said database using SQL queries to associate said value of said identifier and said second data item upon receiving said request.

16. The method as claimed in claim 15, said method further comprising the step of dynamically displaying association of said value of said identifier with said second data item on a graphical user interface connected to said database upon receiving said request.

17. The method as claimed in claim 16, said method further comprising the step of collecting said data relating to said first data item and said second data item by at least one Programmable Logic Controller in said manufacturing process.

18. The method as claimed in claim 17, said method further comprising the step of collecting said data from said Programmable Logic Controller and formatting said data prior to relating said first data item and said second data item to said first data type and said second data type respectively.

19. A system for processing data relating to conditions in a manufacturing process, said data being relateable to one of a plurality of data types, said system comprising:

a data type relation module adapted to receive a first data item of said data and a second data item of said data and to relate said first data item to a first data type of said plurality of data types and said second data item to a second data type of said plurality of data types;

a first data type module adapted to receive said first data item from said data type relation module, to associate said first data item with (i) a first time marker, (ii) a source in said manufacturing process and (iii) an identifier, said value of said identifier to be one of a set of a plurality values relating to a condition of said conditions, said set being expandable during operation of said manufacturing process, said first data type module further adapted to process said set when expanded;

a second data type module adapted to receive said second data item from said data type relation module and to associate a second data item with a second time marker and a source in said manufacturing process;

a database adapted to communicate with said first data type module and said second data type module and to store said first data item and said second data item; and

an output module connected to said database adapted to receive a request and to associate said value of said identifier associated with said first data item with said second data item if;

said first time marker associated with said first data item corresponds to said second time marker associated with said second data item; and

said source associated with said first data item corresponds to said source associated with said second data item,

wherein said value of said identifier indicates one of;

a) identity of an article processed during a first time interval indicated by said first time marker; and

b) a status of said manufacturing process during said first time interval indicated by said first time marker.

20. The system as claimed in claim 19, wherein, when said value of said identifier indicates said article processed during said first time interval, said article is one of:

a1) a part processed;

a2) a batch of parts processed; and

a3) a model processed.

21. The system as claimed in claim 19, wherein, when said value of said identifier indicates status of said manufacturing process during said first time interval, said status is a shift identifier identifying a particular work shift in which parts are processed.

22. The system as claimed in claim 19, wherein said first time marker indicates a start time for said first time interval.

23. The system as claimed in claim 22, wherein said first time marker further indicates an end time for said first time interval, said start time and said end time indicating a duration of said first time interval.

24. The system as claimed in claim 23, wherein said second time marker indicates one of a point in time and a second time interval.

25. The system as claimed in claim 24, wherein said second time marker is said point in time and said first time marker corresponds to said second time marker if said point in time occurs within said first time interval.

26. The system as claimed in claim 24, wherein said second time marker is a second time interval and said first time marker corresponds to said second time marker if at least a portion of said second time interval occurs within said first time interval.

27. The system as claimed in claim 24, wherein said second data type is one of:

a) an accumulator data type, said second time marker is said second time interval and said second data type module is further adapted to associate said second data item with an accumulator value, said accumulator value relating to a count for said second time interval;

b) an event data type, said second time marker is said point in time and said second data type module is further adapted to associate said second data item with an event value, said event value relating to a process variable for said point in time; and

c) an incident data type, said second time marker is said second time interval and said second data type module is further adapted to associate said second data item with an incident value, said incident value relating to an incident occurring in said second time interval.

28. The system as claimed in claim 27, wherein said second data type is an incident data type and said second data type module is further adapted to associate a priority level to said incident value to prioritize said second data item against another data item of said second data type associated with data relating to a condition in said manufacturing process.

29. The system as claimed in claim 24, wherein said source is one of a machine, a portion of a machine and a group of machines in said manufacturing process.

30. The system as claimed in claim 29, said system further comprising a record formatting module for communication of said database with said first data type module and said second data type module, said record formatting module adapted to receive said first data item and said second data item from said first data type module and said second data type module, to format each of said first data item and said second data item into a message for inserting a database record into said database and to insert each said database record formed from said first data item and said second data item into a table in said database.

31. The system as claimed in claim 30, wherein said record formatting module comprises a first message manager adapted to receive said first data item and said second data item from said first data type module and said second data type module and to format each of said first data item and said second data item into a message for inserting a database record into said database and a second message manager adapted to insert each said database record formed from said first data item and said second data item into a table in said database.

32. The system as claimed in claim 31, wherein said record formatting module further comprises a message queue connected to said first message manager and said second message manager, said message queue adapted to queue messages received from said first message manager and said second message manager is further adapted to retrieve each said message queued in said message queue for insertion of said database record associated therewith into said table in said database.

33. The system as claimed in claim 32, wherein said output module is adapted to access said database using SQL queries to associate said value of said identifier and said second data item upon receiving said request.

34. The system as claimed in claim 33, wherein said output module includes a graphical user interface connected to said database adapted to dynamically display association of said value of said identifier with said second data item on upon receiving said request.

35. The system as claimed in claim 34, wherein said graphical user interface is adapted to obtain an input from a user of said system regarding said request and to format said association of said value of said identifier with said second data item in a report for display to said user.

36. The system as claimed in claim 35, said system further comprising at least one Programmable Logic Controller adapted to collect and to forward said data relating to said first data item and said second data item to said data type relation module.

37. The system as claimed in claim 36, said system further comprising an OLE for Process Control server adapted to receive said data from said at least one Programmable Logic Controller and to format said data for said data type relation module.

38. The system as claimed in claim 19, wherein said database contains configuration regarding collection parameters for said data relating to said conditions in said manufacturing process and said system further comprises a configuration management module communicating with said database, said configuration management module adapted to receive an input for independently changing one collection parameter of said collection parameters and adapted to update said one collection parameter in said database while said system is operating.

39. The system as claimed in claim 38, wherein said configuration management module is further adapted to update said one collection parameter while said output module is operating to receive said request and associate said value of said identifier with said second data item.

40. A system for processing data relating to conditions in a manufacturing process, said data being relateable to a plurality of data types including an identifier data type, an accumulator data type, an event data type and an incident data type, each data type of said plurality of data types including an association with a time marker and a source in said manufacturing process, said system comprising:

a data type relation module adapted to receive said data and to process said data into one data type of said plurality of data types;

an identifier data type module adapted to receive said data from said data type relation module if said data is related to said identifier data type, to associate a value of an identifier associated with said identifier data type with one value of a plurality values in a set relating a selection of said conditions to said identifier date type, to allow expansion of said set during operation of said manufacturing process, to process said set when expanded and to prepare said data for storage;

an accumulator data type module adapted to receive said data from said data type relation module if said data is related to said accumulator data type and to prepare said data for storage;

an event data type module adapted to receive said data item from said data type relation module if said data is related to said event data type and to prepare said data for storage; and

an incident data type module adapted to receive said data item from said data type relation module if said data is related to said incident data type and to prepare said data for storage;

a data processing module adapted to receive said data for storage from each of said identifier, accumulator, event and incident data type modules and for generating a request to store said data for storage;

a database adapted to receive said request and to store said data for storage related to said request in a data structure; and

an output module adapted to receive a query relating to identifying data associated with said identifier data type and to process said query by associating a value of an identifier associated with said identifying data with a second data item, said second data item being one of said accumulator, event and incident data types, if;

a time marker associated with said identifying data corresponds to a time marker associated with said second data item; and

a source associated with said identifying data corresponds to a source associated with said second data item,

wherein said value of said identifier indicates one of;

a) an identity of an article processed during an identifying time interval associated with a time marker related to said identifying data; and

b) a status of said manufacturing process during said identifying time interval.