On-line alignment of a process analytical model with actual process operation
First Claim
1. A method of aligning an on-line process run to a process model having a model trajectory for each of a multiplicity of process variables, the method comprising:
- receiving, at a computer device, value data from the on-line process run indicative of a current value for each of the multiplicity of process variables at a particular sample time;
storing the received value data from the on-line process run in a computer readable memory;
for each of the multiplicity of process variables, using the computer device to determine a plurality of distances corresponding to a plurality of model scan positions, each of the plurality of distances indicating a distance between the current value of the process variable and a model trajectory value for that process variable within the process model at the corresponding one of the plurality of model scan positions;
for each of the plurality of model scan positions, using a computer device to sum the ones of the plurality of distances determined for each of the multiplicity of the process variables that correspond to the model scan position to produce, for each of plurality of model scan positions, a summed distance;
using a computer device to determine a minimum summed distance from the summed distances determined for the plurality of model scan positions; and
selecting one of the plurality of model scan positions associated with the determined minimum summed distance as the model scan position to which the on-line process run is currently aligned.
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Abstract
A batch modeling and analysis system uses a simple and computationally inexpensive technique to align data collected from an on-going, currently running or on-line batch process with a batch model formed for the batch process so as to enable the reliable determination of the current operational state of the on-line batch process with respect to the batch model. This data alignment technique enables further statistical processing techniques, such as projection to latent sources (PLS) and principle component analysis (PCA) techniques, to be applied to the on-line batch data to perform analyses on the quality of the currently running batch. These analyses, in turn, provide useful information to a user, such as a batch operator, that enables the user to determine the quality of the batch at the present time, based on the batch model, and the likelihood that the desired batch output quality metrics will be reached at the end of the batch run.
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Citations
39 Claims
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1. A method of aligning an on-line process run to a process model having a model trajectory for each of a multiplicity of process variables, the method comprising:
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receiving, at a computer device, value data from the on-line process run indicative of a current value for each of the multiplicity of process variables at a particular sample time; storing the received value data from the on-line process run in a computer readable memory; for each of the multiplicity of process variables, using the computer device to determine a plurality of distances corresponding to a plurality of model scan positions, each of the plurality of distances indicating a distance between the current value of the process variable and a model trajectory value for that process variable within the process model at the corresponding one of the plurality of model scan positions; for each of the plurality of model scan positions, using a computer device to sum the ones of the plurality of distances determined for each of the multiplicity of the process variables that correspond to the model scan position to produce, for each of plurality of model scan positions, a summed distance; using a computer device to determine a minimum summed distance from the summed distances determined for the plurality of model scan positions; and selecting one of the plurality of model scan positions associated with the determined minimum summed distance as the model scan position to which the on-line process run is currently aligned. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of performing analysis of an on-line process run of a batch process, comprising:
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generating, on a computer device, a statistical model having a model trajectory for each of a multiplicity of process variables prior to the on-line process run, the statistical model having a number of model scan positions; storing the statistical model in a computer readable memory; receiving, at a computer device, data from the on-line process run indicative of a current value for each of the multiplicity of process variables at a most recent time of measurement; using the computer device to analyze the current value for each of the multiplicity of process variables to determine which of the number of model scan positions to which the on-line process run is aligned, wherein using the computer device to analyze the current value for each of the multiplicity of process variables includes; for each of the multiplicity of process variables, determining a distance between the current value of the process variable of the on-line process run and a model trajectory for that process variable within the process model at each of a plurality of model scan positions; for each of the plurality of model scan positions, summing the distances determined for the multiplicity of the process variables that correspond to the respective model scan position to produce a summed distance; determining a minimum summed distance from the summed distances determined for the plurality of model scan positions; and selecting the model scan position associated with the determined minimum summed distance as the model scan position to which the on-line process run is currently aligned; and performing an analysis on the on-line data based on the determined alignment. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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29. A computer device for use in aligning an on-line batch process run to a batch process model having a model trajectory for each of a multiplicity of batch process variables, comprising:
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a non-transitory computer readable memory having a computer implemented application stored thereon, the application including; a first routine that receives, at a computer device running the first routine, value data from the on-line batch process run indicative of a current value for each of the multiplicity of batch process variables at a particular sample time; a second routine that stores the received value data from the on-line batch process run in a computer readable memory; a third routine that, for each of the multiplicity of batch process variables, determines a plurality of distances corresponding to a plurality of model scan positions, each of the plurality of distances indicating a distance between the current value of the batch process variable and a model trajectory value for that batch process variable within the batch process model at the corresponding one of the plurality of model scan positions; a fourth routine that, for each of the plurality of model scan positions, sums the ones of the plurality of distances determined for each of the multiplicity of the batch process variables that correspond to the model scan position to produce, for each of plurality of model scan positions, a summed distance; a fifth routine that determines a minimum summed distance from the summed distances determined for the plurality of model scan positions; and a sixth routine that selects one of the plurality of model scan positions associated with the determined minimum summed distance as the model scan position to which the on-line batch process run is currently aligned. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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Specification