Enhanced flexible process optimizer

• US 7,756,684 B2
• Filed: 05/07/2007
• Issued: 07/13/2010
• Est. Priority Date: 01/26/2004
• Status: Active Grant

• Current Assignee: Ranko IP Series of Ranko, LLC
• Original Assignee: Ranko IP Series of Ranko, LLC
• Inventors: Bhateja, Chander P., Bhateja, Anjali K., Bhateja, Rajiv K.
• Primary Examiner(s): Dunn; Drew A
• Assistant Examiner(s): Cherry; Stephen J
• Application Number:
  US11/744,915
• Publication Number:
  US 20070203671A1
• Time in Patent Office: 1,163 Days
• Field of Search: 700/3, 700/32, 700/7, 700/87, 700/96, 702/106, 702/179, 702/189
• US Class Current: 702/189
• CPC Class Codes: B24B 51/00 Arrangements for automatic control of a series of individual steps in grinding a workpiece if applicable to other machine tools, G05B takes precedence
• CPC Class Codes: G05B 13/024 in which a parameter or coefficient is automatically adjusted to optimise the performance
• 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: G07C 3/005 during manufacturing process
• CPC Class Codes: G07C 3/146 during manufacturing process

Abstract

A flexible process optimizer for recording and analyzing various parameters to improve the efficiency of a production process. The flexible process optimizer acquires and conditions signals from a variety of transducers mounted on a production machine. Through qualitative and quantitative data analysis, specific aspects are of the production process which need improvement are identified. The qualitative evaluation looks at the presence, absence, or duration of certain features of the production cycle as revealed by the sensor data. The quantitative evaluation of data involves the computation of certain data attributes. By providing useful data acquisition and data analysis tools, necessary adjustments are made to the required parameters of the production process to provide improved efficiency. The results of the changes are immediately verifiable using the flexible process optimizer.

Claims

1. An apparatus for monitoring a production process performed by a production machine, said apparatus comprising:

a main circuit including a plurality of module slots in which a plurality of sensor modules may be installed, the module slots for providing electrical connections between the main circuit and the sensor modules installed in the module slots;

a first sensor module installed in one of the plurality of module slots, the first sensor module for receiving a sensor signal related to the production process, the first sensor module including;

a switching circuit for passing the sensor signal via an electrical connection in the module slot to the main circuit; and

one or more amplifiers for receiving the sensor signal from the switching circuit and adjusting offset and gain of the sensor signal;

a second sensor module installed in one of the plurality of module slots, the second sensor module for receiving the sensor signal from the first sensor module via the main circuit, the second sensor module including one or more amplifiers for adjusting offset and gain of the sensor signal independently of the offset and gain provided by the one or more amplifiers in the first sensor module;

a processing device in communication with the main circuit for receiving the sensor signal from the first sensor module and the sensor signal from the second sensor module and for processing the sensor signal from the first sensor module independently of the sensor signal from the second sensor module;

a display device for generating a visual representation of the sensor signal from the first sensor module and the sensor signal from the second sensor module; and

an input device in communication with the processing device, the input device for accepting commands from a user to control the processing device to selectively modify the visual representation of the sensor signal from the first sensor module and the sensor signal from the second sensor module on the display device.

2. The apparatus of claim 1 wherein

the processing device processes the sensor signal from the first sensor module at a first amplitude scale and the sensor signal from the second sensor module at a second amplitude scale that is different from the first amplitude scale, and

the display device generates the visual representation of the sensor signal from the first sensor module at the first amplitude scale and generates the visual representation of the sensor signal from the second sensor module at the second amplitude scale.

3. The apparatus of claim 1 wherein

the processing device processes the sensor signal from the first sensor module at a first time scale and the sensor signal from the second sensor module at a second time scale that is different from the first time scale, and

the display device generates the visual representation of the sensor signal from the first sensor module at the first time scale and generates the visual representation of the sensor signal from the second sensor module at the second time scale.

4. The apparatus of claim 1 wherein the display device generates a graphic overlay of the sensor signal from the first sensor module and the sensor signal from the second sensor module.

5. The apparatus of claim 4 wherein the input device is further operable to accept commands from the user to control one or more of an amplitude scale and a time scale of one or more of the sensor signal from the first sensor module and the sensor signal from the second sensor module in the graphic overlay, and to control the relative amplitude and time scale positioning of the sensor signal from the first sensor module with respect to the sensor signal from the second sensor module.

6. The apparatus of claim 1 further comprising:

a memory device for storing one or both of the sensor signal from the first sensor module and the sensor signal from the second sensor module; and

the display device further operable to generate a graphic overlay of two or more of the sensor signal from the first sensor module in real time, the sensor signal from the first sensor module stored in the memory device, the sensor signal from the second sensor module in real time, and the sensor signal from the second sensor module stored in the memory device; and

the input device for accepting commands from the user to control the processing device to select the signals to be included in the graphic overlay on the display device.

7. The apparatus of claim 1 wherein the display device is further operable to generate a visual representation of the sensor signal from the first sensor module in a first display window and generate a visual representation of the sensor signal from the second sensor module in a second display window.

8. The apparatus of claim 1 wherein the input device is further operable to accept commands from the user to control one or more of an amplitude scale and a time scale of one or more of the sensor signal from the first sensor module and the sensor signal from the second sensor module.

9. The apparatus of claim 1 further comprising a data storage device for storing the sensor data corresponding to one or more of the sensor signal from the first sensor module and the sensor signal from the second sensor module, and the display device is operable to generate the visual representation to include a display of sensor data accessed from the data storage device and a display of real-time sensor data comprising at least one of the sensor signal from the first sensor module and the sensor signal from the second sensor module.

10. The apparatus of claim 9 wherein the sensor data accessed from the data storage device is displayed at an amplitude scale that is different from the amplitude scale at which the real-time sensor data is displayed.

11. The apparatus of claim 9 wherein the sensor data accessed from the data storage device is displayed at a time scale that is different from the time scale at which the real-time sensor data is displayed.

12. The apparatus of claim 1 wherein the processing device is operable to determine a slope of at least one of the sensor signal from the first sensor module and the sensor signal from the second sensor module corresponding to a point in the visual representation on the display device.

13. The apparatus of claim 1 wherein the processing device is operable to determine an area under a curve of at least one of the sensor signal from the first sensor module and the sensor signal from the second sensor module in the visual representation on the display device.

14. The apparatus of claim 1 wherein the processing device is operable to determine maximum and minimum amplitude values of at least one of the sensor signal from the first sensor module and the sensor signal from the second sensor module in the visual representation on the display device.

15. The apparatus of claim 1 wherein the processing device is operable to process the sensor signal from the first sensor module at a first amplitude scale and the sensor signal from the second sensor module at a second amplitude scale that is different from the first amplitude scale, and the display device is operable to generate the visual representation of the sensor signal from the first sensor module at the first amplitude scale and generate the visual representation of the sensor signal from the second sensor module at the second amplitude scale.

16. The apparatus of claim 1 wherein the processing device is operable to process the sensor signal from the first sensor module at a time amplitude scale and the sensor signal from the second sensor module at a second time scale that is different from the first time scale, and the display device is operable to generate the visual representation of the sensor signal from the first sensor module at the first time scale and generate the visual representation of the sensor signal from the second sensor module at the second time scale.

17. The apparatus of claim 1 wherein the first sensor module is calibrated at a first calibration range and the second sensor module is calibrated at a second calibration range, where the second calibration range is dependent upon or independent of the first calibration range.