Manufacturing Cell Data Aggregation Reducing Network Load
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Solution Overview
Problem
Large-scale factories face increased network load, processing capability shortages, and longer response times due to the large volume of data transferred from multiple manufacturing cells to a central production planning apparatus, which also hinders real-time analysis and comparison of working data at the manufacturing site.
Innovation Solution
A control apparatus and system that includes a master cell controller capable of receiving, classifying, and aggregating working data from multiple manufacturing cells, generating integrated and aggregated data by comparing data item lists, and transmitting reduced data volumes externally, allowing for efficient data management and analysis without relying on the central production planning apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If all working data from multiple manufacturing cells is transferred to the central production planning apparatus, then comprehensive data collection is achieved, but network load increases and processing capability becomes insufficient
Solution Approach 1:
The patent divides the centralized data collection system into distributed data processing units at each manufacturing cell. Each cell controller performs local data aggregation and filtering, segmenting the overall data processing task across multiple independent nodes rather than concentrating all processing at the central apparatus.
Solution Approach 2:
The patent extracts and removes redundant or unnecessary data elements before transmission. Each cell controller filters working data to extract only essential information needed for production planning, eliminating duplicate measurements and non-critical parameters from the transmitted data stream.
2Loss of information
If all working data from multiple manufacturing cells is transferred to the central production planning apparatus, then complete monitoring is achieved, but response time increases
Solution Approach 1:
The patent performs preliminary data processing, aggregation, and filtering at each manufacturing cell controller before data transmission. By preparing and condensing data in advance at the source, the system reduces the volume of data requiring transmission and processing at the central apparatus, thereby accelerating overall response time.
3Reliability
If the production planning apparatus is installed in a clean room separated from the working site, then environmental control is maintained, but data analysis and comparison become difficult
Solution Approach 1:
The patent introduces a portable terminal device as an intermediary between the centralized production planning apparatus and operators at the working site. This terminal provides remote access to aggregated working data and analysis results, allowing operators to view and analyze data without physically accessing the clean room environment.
4Loss of information
If data volume from multiple manufacturing cells is significantly increased, then comprehensive analysis capability is enhanced, but network load increases
Solution Approach 1:
The patent merges data from multiple manufacturing cells at the cell controller level before transmission to the central apparatus. By consolidating data from multiple sources into aggregated summaries at intermediate nodes, the system reduces the total volume of data transmitted over the network while preserving essential information for comprehensive analysis.
Data Source
AI summary
There is provided a control apparatus including a receiving part that receives working data of manufacturing cells; a storage part that stores the working data; an item list generation part that classifies the working data for each of the components of each manufacturing cell, and extracts a data item to generate a data item list of a whole of each manufacturing cell; an integrated data generation part that compares a plurality of the data item lists, reads out detailed data of the data items having the same value from the working data stored in the storage part, and generates integrated data; an aggregated working data generation part that combines the integrated data and data other than the integrated data to generate aggregated working data; and a transmission part that externally transmits the aggregated working data.