Cloud-Based Digital Historian for Batch Cooker Data Integration
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Solution Overview
Problem
Current food processing technologies lack the ability to effectively integrate and analyze both online and offline data in batch processing environments, leading to inefficiencies and inaccuracies in quality and safety assessments, which are critical for regulatory compliance and productivity optimization.
Innovation Solution
A cloud-based digital historian system that centralizes data collection and processing, integrating with PLC-based systems to collect and correlate online and offline data, providing real-time insights and recommendations for quality, safety, and productivity improvements through AI-driven analytics and remote support capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cloud-based digital historian system is implemented, then data collection and analysis accuracy is improved, but system complexity and initial cost increase
Solution Approach 1:
The patent introduces a cloud-based digital historian system as an intermediary layer between PLC-based control systems and users. This intermediary centralizes data collection from multiple disconnected systems, performs sophisticated analytics, and presents integrated insights through web-based dashboards, thereby improving data accuracy without requiring direct complex integration between existing systems.
Solution Approach 2:
The patent replaces manual data collection methods (human inspection and logging) and simple online chart recorders with an automated cloud-based digital historian system that continuously collects, correlates, and analyzes both online and offline data, significantly improving measurement precision through automated electronic processes.
2Reliability
If cloud-based digital historian system is implemented, then regulatory compliance and food safety are improved, but initial cost and infrastructure requirements increase
Solution Approach 1:
The patent creates a universal cloud-based platform that serves multiple functions: data collection from various sources, regulatory compliance monitoring, food safety assurance, production optimization, and analytics. This multi-functional system consolidates what would otherwise require multiple separate systems, reducing the total infrastructure burden while improving reliability.
Solution Approach 2:
The system automatically collects data from PLC-based systems, correlates online and offline data, performs analytics, and generates compliance reports without requiring manual intervention. This automation reduces the need for extensive human resources and infrastructure while ensuring consistent regulatory compliance and food safety monitoring.
3Device complexity
If traditional disconnected data collection systems are used, then system simplicity is maintained, but data integration and analysis effectiveness deteriorate
Solution Approach 1:
The patent merges previously disconnected data collection systems (online PLC data and offline manual records) into a single cloud-based digital historian platform. This consolidation enables comprehensive data correlation and analysis that was impossible with separate systems, eliminating information loss while maintaining manageable complexity through centralized architecture.
4Quantity of substance
If manual data collection methods are used, then implementation cost is reduced, but human error and data accuracy increase
Solution Approach 1:
The patent replaces manual data collection methods with automated electronic data acquisition from PLC-based systems and digital offline sources. This substitution eliminates human error in data recording and entry while maintaining cost-effectiveness through cloud-based processing that eliminates the need for extensive manual labor and associated training and oversight costs.
Data Source
AI summary
An industrial batch production system, including at least one industrial automation device, at least one equipment sensor disposed on and operatively coupled to the industrial automation device to obtain on-line data relating to a batch run, an Internet-enabled local controller in electronic communication with the equipment sensors, a cloud link connecting the Internet-enabled local controller with an Internet-based cloud platform, a central server in the cloud platform configured to receive data from the local controller and running a process historian software program having a time series database, and at least one Internet-enabled device configured to receive manually obtained time-stamped offline data relating to the batch run and to transmit the offline data to the central server independently of the Internet-enabled local controller through a VPN or Ethernet. The central server processes the on-line data and off-line data together to provide automatic processing services to optimize and improve batch run production.