Discrete energy assignments for manufacturing specifications

• US 9,406,036 B2
• Filed: 04/24/2009
• Issued: 08/02/2016
• Est. Priority Date: 04/24/2009
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kaufman, Philip John, Walker, Marcia Elaine, Lombardi, Steven Anthony
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Rao, Sheela S
• Application Number:
  US12/429,821
• Publication Number:
  US 20100274377A1
• Time in Patent Office: 2,657 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 90/82 Energy audits or management systems therefor
• CPC Class Codes: Y02P 90/84 Greenhouse gas [GHG] management systems

Abstract

An industrial control system is provided. The system includes tagged data that is collected from a plurality of sustainability factor-associated data sources across an industrial automation environment, where the tagged data is associated with a portion of a process that is attributed to the sustainability factor data sources. A manufacturing model is associated with the tagged data, where the manufacturing model is employed to enhance the efficiencies of the process.

Claims

1. An industrial control system, comprising:

a plurality of discrete monitors configured to acquire a plurality of datasets associated with a plurality of sustainability factors regarding one or more processes within an industrial automation environment, wherein the plurality of sustainability factors comprises energy information and waste information;

a processor configured to;

generate a plurality of tagged datasets based on the plurality of datasets and an association between each of the plurality of datasets with a respective process of the one or more processes;

aggregate the plurality of tagged datasets with respect to the respective process of the one or more processes to generate a plurality of aggregated datasets; and

generate a manufacturing model configured to enhance one or more energy efficiencies of the one or more processes, wherein the manufacturing model comprises an association between each of the plurality of aggregated datasets and the respective process of the one or more processes; and

modifying one or more operation schedules of the one or more processes based on the manufacturing model.

2. The system of claim 1, wherein the one or more processes are associated with a discrete process or a batch process.

3. The system of claim 1, wherein the manufacturing model is a bill of material, an MRP model (material requirement planning), an MES model (manufacturing execution system), an ERP model (enterprise resource planning), an S88 model, or a programming model.

4. The system of claim 3, wherein the programming model includes ladder logic, a sequential function chart, a batch program, or a function block.

5. The system of claim 3, wherein the bill of material includes itemized components of the plurality of sustainability factors regarding the one or more processes that are associated with one or more components of a discrete assembly or steps of a batch process.

6. The system of claim 3, wherein the bill of material includes itemized components of the plurality of sustainability factors regarding the one or more processes that are associated with a subset of discrete components or a subset of batch process steps.

7. The system of claim 3, wherein the bill of material includes itemized components of the plurality of sustainability factors associated with a product listing.

8. The system of claim 7, wherein the bill of material includes a peak demand listing or an electrical usage charge.

9. The system of claim 7, wherein the bill of material includes the waste information.

10. The system of claim 1, wherein the plurality of sustainability factors comprises water usage, expected energy use, a type of energy used, a carbon emission, a recyclability factor, an environmental impact factor, a safety factor, or a utility demand factor.

11. The system of claim 1, further comprising a smart grid component that processes the manufacturing model.

12. The system of claim 1, further comprising a demand response component that employs a mathematical model to modulate a manufacturing process based upon at least one of business rules, regulatory restrictions, or energy availability.

13. The system of claim 1, further comprising a historian component to archive data associated with the plurality of sustainability factors.

14. The system of claim 1, further comprising a simulation component to manage energy in accordance with the manufacturing model.

15. The system of claim 1, wherein the plurality of sustainability factors is associated with user rights, work instructions, schedules, material specifications, an intra-material item specification, or routings.

16. The system of claim 1, wherein the plurality of sustainability factors is captured in accordance with a time synchronization procedure.

17. The system of claim 16, wherein the time synchronization procedure is associated with a 1588 standard.

18. The system of claim 1, wherein the manufacturing model determines a percent of efficiency as a ratio of manufacturing energy consumed and total energy consumed.

19. A method of controlling an industrial process, comprising:

receiving a plurality of datasets from a plurality of energy sources across an automated facility, wherein the plurality of datasets comprise energy information and waste information associated with one or more portions of a process in the automated facility;

generating a plurality of tagged datasets based on an association between the plurality of datasets and a respective portion of the process;

aggregating the plurality of tagged datasets with respect to the respective portion of the process to generate a plurality of aggregated datasets;

adapting a manufacturing specification to record an association between each of the plurality of aggregated datasets and the respective portion of the process; and

processing the manufacturing specification to mitigate energy associated with the automated facility by altering an operation schedule of the respective portion of the process.

20. The method of claim 19, further comprising adjusting an energy grid in view of the plurality of tagged datasets.

21. The method of claim 19, further comprising generating a bill of material from the manufacturing specification, wherein the bill of material includes:

itemized energy consumption data associated with one or more components or one or more process steps of the process, or itemized energy consumption data associated with a products produced by the process.

22. The method of claim 21, further comprising monitoring waste or emissions to update the bill of material.

23. The method of claim 21, further comprising processing the bill of material in a simulator to determine energy savings.

24. An industrial control system, comprising:

means for monitoring one or more sustainability factor-associated energy sources;

means for identifying the sustainability factor-associated energy sources;

means for generating a manufacturing specification that reflects at least one sustainability factor-associated energy source; and

means for generating a bill of material from the manufacturing specification, wherein the bill of material includes itemized components of sustainability factors associated with components of a process or products produced by the process, wherein the sustainability factors comprise energy information and waste information.