Concrete Production History Tracking for Real-Time Quality Control
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Solution Overview
Problem
Conventional systems for managing the production history of concrete products are inadequate as they do not effectively monitor and analyze all production processes, leading to variability in product quality and productivity.
Innovation Solution
An integrated management system utilizing ICT, IoT, and AI to measure and analyze data from aggregate, mixing, molding, curing, and packing processes, including sensor modules and RFID chips for real-time monitoring and data storage, enabling continuous improvement of product quality and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional history management methods are used (checking samples after molding and curing), then the system is simple to operate, but the measurement precision and reliability of production history management are insufficient
Solution Approach 1:
The production process is divided into distinct segments (aggregate process, mixing process, molding process, curing process) with dedicated sensors for each stage. This segmentation allows precise measurement of parameters at each specific process point while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
A centralized server system performs multiple functions including data collection from various sensors, data storage, data analysis, and providing user interfaces. This multi-functional approach improves measurement precision through integrated management while avoiding excessive complexity by consolidating functions into a universal platform.
2Reliability
If comprehensive monitoring of all production processes is implemented, then the reliability of quality management is improved, but the device complexity and cost increase
Solution Approach 1:
Different process stages (aggregate, mixing, molding, curing) are monitored by specialized sensors tailored to each process's specific parameters. This segmentation ensures comprehensive and reliable monitoring of quality-critical parameters at each stage while keeping the overall system organized and manageable through clear functional division.
Solution Approach 2:
The system continuously collects data from sensors throughout production, analyzes the data through the server, and provides feedback for quality control decisions. This feedback mechanism enhances reliability by enabling real-time quality assessment and corrective actions while maintaining systematic complexity through automated control loops.
3Productivity
If real-time data collection and analysis is performed across all processes, then productivity and quality improvement are enabled, but the use of energy and system complexity increase
Solution Approach 1:
Sensors continuously collect data throughout the production process without interruption, enabling real-time monitoring and immediate quality assessments. This continuous data collection improves productivity by eliminating delays between production and quality evaluation, while energy consumption is managed efficiently through automated processing and strategic placement of sensors.
Solution Approach 2:
The system automatically collects, stores, and analyzes production data without requiring manual intervention at each stage. This self-service capability improves productivity by enabling autonomous quality control and reduces energy consumption associated with manual monitoring and data processing operations.
Data Source
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AI summary
The present invention relates to an integrated management system for production history of a concrete product. More particularly, the present invention relates to an integrated management system for production history of a concrete product, the system being capable of: dividing all production processes for from aggregate that is raw material to a complete concrete product such as concrete blocks; providing information required for each process and measurement values to the manager and the operator by using generic technologies such as ICT, IoT, AI, etc. so that the manager and the operator reflect them in the production processes in real time; and integrally managing and analyzing the information and the measurement values so as to continuously produce of concrete products having high quality.