Batch Stage Analytics Decoupled from Recipe Events
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Solution Overview
Problem
Existing batch control analytics methods rely on identifying stages based on batch events, which may not align with actual process dynamics, leading to inaccurate model application and reduced reliability, as they tie stage boundaries to the start and end of procedural elements in a batch recipe, rather than the conditions of process parameters.
Innovation Solution
Determining the current stage in a batch process independently of batch events by calculating a batch stage parameter based on process control data, allowing for precise identification of stage boundaries and accurate model application by aligning stages with process parameter conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stage boundaries are tied to batch events (start/end of procedures, unit procedures, operations, or phases in batch recipe), then the control system follows a structured procedural framework, but the stage identification does not align with actual process dynamics, leading to inaccurate model application
Solution Approach 1:
The patent changes the parameter used for stage identification from batch event markers (procedural elements) to continuous process parameter values. By monitoring process parameters (temperature, pressure, flow rates, etc.) and identifying stages based on their actual values and trends, the system achieves accurate alignment with process dynamics while maintaining manageable complexity through systematic parameter monitoring.
Solution Approach 2:
The patent replaces the mechanical/procedural system of batch event-based stage identification with a data-driven system using process parameter analysis. Instead of relying on discrete procedural markers, the system continuously monitors and analyzes process parameters to dynamically identify stages, substituting rigid procedural structures with flexible, condition-based identification.
2Reliability
If stage identification is based on batch events in batch recipe, then the system maintains procedural structure, but the analytics reliability is reduced due to misalignment with actual processing conditions
Solution Approach 1:
The patent implements feedback by continuously monitoring process parameters and using this information to identify and define batch stages. The system feeds back actual process condition data (temperature, pressure, flow rates) to dynamically adjust stage identification, ensuring that analytics are applied during the correct process stages and preventing loss of critical process condition information.
Solution Approach 2:
The patent performs preliminary action by establishing the relationship between process parameters and process stages before analytics are applied. By pre-defining how process parameter values correspond to specific batch stages, the system ensures that the correct analytics models are ready and applicable when needed, improving reliability without losing process condition information.
Data Source
AI summary
Methods and apparatus to define stages for multi-variate batch control analytics are disclosed. An example method includes determining, with the processor, a current stage in a current batch process based on a current value of a batch stage parameter. The current value of the batch stage parameter determined based on process control data associated with process parameters in the current batch process. The current stage determined independent of batch events defined by at least one of a start or an end of procedures, unit procedures, operations, or phases in a batch recipe. The example method further includes applying, with the processor, a model to the current batch process, the model corresponding to the current stage.