Method, system and device for predictive error recognition in a plant
First Claim
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1. A method for predictive recognition of errors in a manufacturing system, said method comprising the steps of:
- archiving a plurality of error patterns that previously occurred in the manufacturing system, the archived error patterns created by statistical methods;
monitoring manufacturing system data in real-time;
maintaining an evaluation unit with input data that defines functional relationships of plant components, on-site relationships of plant components, hierarchical relationships between controllers and field devices, and relationships between enterprise resource planning and manufacturing execution systems, wherein conditions for the manufacturing system data to be monitored are defined in the evaluation unit and submitted to peripheral devices in the manufacturing system based on a hierarchical plant model, plant topology, and automation topology to reduce the amount of the manufacturing system data to be analyzed by the evaluation unit;
comparing the monitored data with the archived error patterns in real-time to predict imminent errors likely to occur in the manufacturing system;
providing recommended actions to prevent the predicted imminent errors; and
refining the plurality of error patterns in an automated learning module that receives indications of relevance in matching of the monitored data to the archived error patterns and receives indications of success of the error predictions and recommended actions, and automatically modifies the archived error patterns to improve the relevance indications and the success indications.
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Abstract
Method, system and device for predictive recognition of errors in a manufacturing system, said comprising: online monitoring of data of the manufacturing system; and online comparing said data with archived error patterns to predict errors supposed to occur in the manufacturing system; whereby the archived error patterns are built and recognized by statistical methods and data mining methods. The present invention can be used for discrete or continuous or batch processes.
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Citations
18 Claims
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1. A method for predictive recognition of errors in a manufacturing system, said method comprising the steps of:
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archiving a plurality of error patterns that previously occurred in the manufacturing system, the archived error patterns created by statistical methods; monitoring manufacturing system data in real-time; maintaining an evaluation unit with input data that defines functional relationships of plant components, on-site relationships of plant components, hierarchical relationships between controllers and field devices, and relationships between enterprise resource planning and manufacturing execution systems, wherein conditions for the manufacturing system data to be monitored are defined in the evaluation unit and submitted to peripheral devices in the manufacturing system based on a hierarchical plant model, plant topology, and automation topology to reduce the amount of the manufacturing system data to be analyzed by the evaluation unit; comparing the monitored data with the archived error patterns in real-time to predict imminent errors likely to occur in the manufacturing system; providing recommended actions to prevent the predicted imminent errors; and refining the plurality of error patterns in an automated learning module that receives indications of relevance in matching of the monitored data to the archived error patterns and receives indications of success of the error predictions and recommended actions, and automatically modifies the archived error patterns to improve the relevance indications and the success indications. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A computerized system for predictive recognition of errors in a manufacturing system, comprising:
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a mechanism for archiving a plurality of error patterns that previously occurred in the manufacturing system, the archived error patterns minimized by statistical methods; an evaluation unit with input data that defines functional relationships of plant components, on-site relationships of plant components, hierarchical relationships between controllers and field devices, and relationships between enterprise resource planning and manufacturing execution systems, wherein conditions for the manufacturing system data to be monitored are defined in the evaluation unit and submitted to peripheral devices in the manufacturing system based on a hierarchical plant model, plant topology, and automation topology to reduce the amount of the manufacturing system data to be analyzed by the evaluation unit; a mechanism for monitoring manufacturing system data in real-time; a ring buffer for storing the monitored data; a mechanism for comparing the monitored data with the archived error patterns in real-time to predict imminent errors likely to occur in the manufacturing system, and for providing recommended action; and an automated learning module that receives indicators of relevance in matching of the monitored data to the archived error patterns, and receives indicators of success of the error predictions and recommended actions, and automatically modifies the archived error patterns to improve the relevance indicators and the success indicators. - View Dependent Claims (12, 13)
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14. A device for predictive recognition of errors in a manufacturing system, comprising:
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a mechanism for archiving a plurality of error patterns that previously occurred in the manufacturing system, the archived error patterns compressed by statistical methods or data mining methods; a mechanism for monitoring manufacturing system data in real-time; a mechanism for storing the monitored data in a ring buffer; an evaluation unit with input data that defines functional relationships of plant components, on-site relationships of plant components, hierarchical relationships between controllers and field devices, and relationships between enterprise resource planning and manufacturing execution systems, wherein conditions of the manufacturing system data to be monitored are defined in the evaluation unit and submitted to peripheral devices in the manufacturing system based on a hierarchical plant model, plant topology, and automation topology to reduce the amount of the manufacturing system data to be analyzed by the evaluation unit; a mechanism for comparing the monitored data with the archived error patterns in real-time to predict imminent errors likely to occur in the manufacturing system, and for providing recommended action; and an automated learning module that receives indicators of relevance in matching of the monitored data with the archived error patterns, and receives indicators of success of the error predictions and recommended actions, and automatically modifies the archived error patterns to improve the relevance indicators and the success indicators. - View Dependent Claims (15, 16, 17, 18)
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Specification