ENHANCED FLEXIBLE PROCESS OPTIMIZER

• US 20070203671A1
• Filed: 05/07/2007
• Published: 08/30/2007
• 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, Rajiv, Bhateja, Anjali, Bhateja, Chander
• Granted Patent: US 7,756,684 B2
• Time in Patent Office: Days
• US Class Current: 702/188
• 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. A method of monitoring a production process using a hardware monitoring device having at least one sensor module installed therein, the method comprising the steps of:

(a) acquiring sensor data using the at least one sensor module;

(b) splitting the sensor data from the at least one sensor module into a first signal and a second signal;

(c) processing the first and second signals independently; and

(d) generating a visual representation of the first and second signals substantially simultaneously on a display device.

2. The method of claim 1 wherein step (d) comprises generating a visual representation of the first signal in a first display window and generating a visual representation of the second signal in a second display window.

3. The method of claim 1 wherein step (d) comprises generating an overlay of the first signal and the second signal in a single display window.

4. The method of claim 3 further comprising controlling relative positions of the first signal and second signal in the display window.

5. The method of claim 1 wherein step (c) comprises adjusting one or more of an amplitude scale and a time scale of one or more of the first and second signals as step (a) is continuously performed.

6. The method of claim 1 further comprising:

(e) pausing acquisition of the sensor data;

(f) determining a duration of a time period during which sensor data acquisition is paused; and

(g) determining a begin time and end time for the time period during which data acquisition is paused.

7. The method of claim 1 further comprising:

(e) storing the sensor data for one or more of the first signal and the second signal on a data storage device; and

(f) accessing the sensor data stored on the data storage device,

wherein step (d) comprises generating 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 first and second signals.

8. The method of claim 7 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.

9. The method of claim 7 wherein the sensor data accessed from the data storage device is displayed at an time scale that is different from the time scale at which the real-time sensor data is displayed.

10. The method of claim 1 further comprising determining a slope of at least one of the first and second signals corresponding to a point in the visual representation on the display device.

11. The method of claim 1 further comprising determining an area under a curve of at least one of the first and second signals in the visual representation on the display device.

12. The method of claim 1 further comprising determining maximum and minimum amplitude values of at least one of the first and second signals in the visual representation on the display device.

13. The method of claim 1 further comprising continuously monitoring the amplitude of at least one of the first and second signals at a particular point in time in the visual representation on the display device.

14. The method of claim 1 wherein:

step (c) further comprises processing the first signal at a first amplitude scale and the second signal at a second amplitude scale that is different from the first amplitude scale; and

step (d) further comprises generating the visual representation of the first signal at the first amplitude scale and generating the visual representation of the second signal at the second amplitude scale.

15. The method of claim 1 wherein:

step (c) further comprises processing the first signal at a first time scale and the second signal at a second time scale that is different from the first time scale; and

step (d) further comprises generating the visual representation of the first signal at the first time scale and generating the visual representation of the second signal at the second time scale.

16. The method of claim 1 further comprising calibrating the at least one sensor module at a first calibration range for the first signal and at a second calibration range for the second signal, where the first calibration range is different from the second calibration range.

17. The method of claim 1 further comprising:

(e) monitoring the sensor data to detect interruptions in acquisition of the sensor data;

(f) generating an alert signal upon detection of an interruption in the acquisition of the sensor data; and

(g) pausing processing of the sensor data upon detection of an interruption in the acquisition of the sensor data.

18. A method of monitoring a production process using a hardware monitoring device having at least one sensor module installed therein, the method comprising the steps of:

(a) acquiring sensor data using the at least one sensor module;

(b) generating a visual representation of the sensor data on a display device in an amplitude versus time format;

(c) applying a negative amplitude offset to the sensor data when the amplitude of the sensor data exceeds a maximum threshold, thereby preventing the amplitude of the sensor data from drifting above a maximum displayable amplitude on the display device; and

(d) applying a positive amplitude offset to the sensor data when the amplitude of the sensor data falls below a minimum threshold, thereby preventing the amplitude of the sensor data from drifting below a minimum displayable amplitude on the display device.

19. The method of claim 18 further comprising storing the amplitude offsets over time to keep a history of sensor data drift.

20. A method of monitoring a production process using a hardware monitoring device having at least one sensor module installed therein, the method comprising the steps of:

(a) calibrating the at least one sensor module over a first amplitude range;

(b) acquiring sensor data using the at least one sensor module over the first amplitude range; and

(c) generating a visual representation of the sensor data on a display device, wherein the visual representation is over a second amplitude range that is less than or greater than the first amplitude range,

wherein steps (b) and (c) are performed substantially simultaneously.

21. A method of monitoring a production process using a hardware monitoring device having at least one sensor module installed therein, the method comprising the steps of:

(a) acquiring sensor data using the at least one sensor module;

(b) generating a first visual representation of the sensor data on a display device, wherein the first visual representation has a first time scale;

(c) generating a second visual representation of the sensor data on the display device, wherein the second visual representation has a second time scale that is different from the first time scale; and

(d) switching from the first visual representation to the second visual representation on the display device while continuously performing step (a).

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

at least one sensor module for generating sensor signals related to the production process;

a switching circuit in communication with the at least one sensor module, the switching circuit for splitting the sensor signals into a first signal and a second signal;

a processing device in communication with the switching circuit for receiving and processing the first and second signals independently;

a display device for generating a visual representation of the first and second signals; 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 first and second signals on the display device.

23. The apparatus of claim 22 wherein

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

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

24. The apparatus of claim 22 wherein

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

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

25. The apparatus of claim 22 wherein the display device generates a graphic overlay of the first and second signals.