System for monitoring a continuous manufacturing process

• US 5,717,456 A
• Filed: 03/06/1995
• Issued: 02/10/1998
• Est. Priority Date: 03/06/1995
• Status: Expired due to Term

• Current Assignee: Monitoring Technology Corporation
• Original Assignee: Champion International Corporation (International Paper Company)
• Inventors: Grapes, Kenneth D., Fiore, Leonard F., Rudt, Robert J.
• Primary Examiner(s): Chin, Tommy P.
• Assistant Examiner(s): Le, Vu
• Application Number:
  US08/399,235
• Time in Patent Office: 1,072 Days
• Field of Search: 348/88, 348/86, 348/8, 348/92, 348/125, 348/128, 348/94
• US Class Current: 348/88
• CPC Class Codes: G01N 21/8903 using a multiple detector array
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 2219/31442 Detect if operation on object has been executed correctly in each station
• CPC Class Codes: G05B 2219/31447 Process error event detection and continuous process image detection, storage
• CPC Class Codes: G07C 3/146 during manufacturing process
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The invention is a system for monitoring a process in which process data relating to a predetermined characteristic of the process is collected and stored in digital format and extracted based upon a predetermined criterion for display. A plurality of monitors are strategically positioned at various locations of interest to observe the predetermined characteristic. Data obtained by the monitors are converted into digital format and stored. A central control is provided for retrieving the digital data in accordance with a predetermined criterion and transmitting the retrieved data to a display unit. The predetermined criterion for display may be specified as a deviation from the predetermined characteristic, and a plurality of deviation detectors may be coupled to the system for obtaining and relaying information relating to such deviations. Upon deviation, the central control may be adapted to retrieve digital data based on time and location of the deviation.

Claims

1. A monitoring system for monitoring the manufacture of a continuous web of paper having one or more pre-determined characteristics in a paper manufacturing machine comprising:

a plurality of monitoring means which comprises one or more video cameras for monitoring the paper web, each monitoring means addressing the paper web at a different location of interest along the paper manufacturing machine and for producing a video image of the paper web at the location;

digital converting means for converting the video image into a digitized video signal;

digital data storage means for receiving said digitized video signal and storing digitized segments thereof, each of which comprises a plurality of digitized clips, said digitized segments and clips of a predetermined length covering real time operation of said machine, said digitized segments being stored such that earlier prior stored digitized data in said segment is removed as new digitized data is stored in said segment to maintain said stored segment at or about said predetermined length;

computer control means for controlling the operations of said monitoring system, said means in communication with said digital data storage means, said computer control means in communication with a distributive control system for controlling said machine, said control system having one or more deviation detectors for detecting deviations from predetermined characteristics as said paper web passes through said machine; and

one or more video monitors in communication with said computer control means and for displaying the image of digitized video signals under the control of said computer control means;

wherein an occurrence of a deviation from the predetermined characteristics of said web, said distributive control system transmits a deviation signal comprising the time, date and location of said deviation event to said computer control means, and in response thereto said computer control means identifying the digitized data segment corresponding to said deviation event, extracting the deviation event clip, the preceding clip preceding said break event clip to form a display clip and displaying said display clip on a video monitor.

2. System of claim 1 wherein at least one digital converting means is in communication with at least one video camera and at least on digital data storage means is in communication with at least one digital converting means.

3. System of claim 2 wherein on receipt of said deviation event signal at the time of said deviation, said computer control means identifies a video camera proximate to said deviation detector detecting said deviation event, freezes operations of digital memory storage means for such camera, identifies the digitized data segment corresponding to said deviation event by correlating the time of said segment with the time of said deviation event, extracting the deviation event clip which correlates to the time of said deviation event and the preceding clip preceding said deviation event clip and the subsequent clip following said deviation event clip, splicing said deviation event clip, said preceding clip and said subsequent in chronological order to form a display clip and displaying said display clip on said video monitor.

4. System of claim 3 which further comprises:

means for transmitting process data from the distributive control system with said break event signal;

library means for storage of display clips and associated process data; and

means for accessing said display clips and process data stored in said library.

5. System of claim 1 wherein said event is selected from the group consisting of a break in said web, a hole in said web and a change in a surface characteristic of said web.

6. System of claim 1 wherein said computer control means is also for controlling said digital data storage means.

7. System of claim 1 wherein said distributive control system is also for communicating process master time and date information to said computer control system.

8. A monitoring system for continuously monitoring a process for the manufacture of a product, said process comprising:

a plurality of monitoring means for continuously monitoring a pre-determined characteristic of the process and collecting monitored data, each monitoring means addressing a different location of interest of the process, and each said monitoring means for monitoring and collecting data in real time relative to said location;

data converting means for converting said collected data into digitized data;

digital data storage means for storing segments of said digitized data, each of said segments comprised of one or more digitized data clips, said segments and said clips of pre-determined lengths which cover the operations of said process at a relevant location over a pre-determined period of time, said digitized data segments being stored such that as new digitized data is stored in said segment, earlier prior stored digitized data in said segment is removed from said segment to maintain said segment at or about said pre-determined length;

a distributive control system for controlling the process, said control system having one or more deviation detectors for monitoring said pre-determined characteristic and for detecting deviation events in said pre-determined characteristic, each of said detectors addressing a different location of interest along the process and for transmitting a signal of said deviation event, and the time and location of said event; and

control means in communication with said control system and said digital data storage means, said control means for controlling said monitoring system and for extracting one or more digitized data clips on receipt of said deviation event signal to form one or more extracted clips, said control means also for identifying data storage means containing said digitized data segment corresponding to the time and the location of said deviation event, for extracting said deviation event clip to form a display clip and for displaying said display clip.

9. System of claim 8 wherein said process is a continuous process for the manufacture of a product.

10. System of claim 9 wherein said process comprises a plurality of steps and wherein there is at least one monitoring means for each of said steps.

11. System of claim 8 wherein a plurality of monitoring means address a single location, each in communication with a digital data converting means which is in communication with a digital data storage means, said control means extracts one or more digitized data clips from each of said storage means and displays said extracted clips.

12. A system of claim 11 wherein each of said monitoring means monitors a different pre-determined characteristic.

13. A system of claim 12 wherein said monitoring means are different.

14. System of claim 8 wherein said distributive control system is also for communicating process data relating to the operation of the process to said control means.

15. System of claim 14 which further comprises:

library means in communication with said control means for storage of display clips and process data relating to the operation of the machine at the time of deviation, said library also for display of said stored display clips and process data.

16. System of claim 15 wherein said control means extracts the event clip recording said event and the clip immediately preceding said event clip, splicing said clips in chronological order to form a display clip and displaying said display clip.

17. System of claim 16 wherein said control means extracts the event clip recording said event, the clip immediately preceding said event clip, the clip immediately following said event clip, splicing said clips in chronological order to form a display clip and displaying said display clip.

18. System of claim 8 wherein said pre-determined criterion is a deviation event in which there is a deviation in said pre-determined characteristic.

19. System of claim 8 wherein the process is a continuous process for the manufacture of a product.