Diagnostic System Using Reused Process Models
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Solution Overview
Problem
Diagnostic systems in manufacturing environments face significant challenges in efficiently reducing mean time to repair (MTTR) due to the extensive effort required to capture all potential failure modes, leading to prolonged configuration of desired behaviors.
Innovation Solution
A diagnostic system that utilizes a 'known good' process model developed during the design phase, incorporating elements reused from the design process, compares actual process states to expected states using a difference engine, and provides real-time feedback for fault detection and remediation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diagnostic systems attempt to capture all potential failure modes, then diagnostic completeness is improved, but configuration time and development effort increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-configuring the process model during the design phase with all potential failure modes captured beforehand. This allows the diagnostic system to reuse the pre-built model without requiring extensive configuration when deploying diagnostics in the manufacturing environment, thus reducing configuration time while maintaining diagnostic completeness
Solution Approach 2:
The patent uses copying by creating a virtual process model that replicates the actual manufacturing process. This model is copied from the design phase and reused for diagnostic purposes, eliminating the need to rebuild diagnostic configurations from scratch and significantly reducing development effort while maintaining comprehensive failure mode coverage
2Measurement precision
If a detailed process model is developed during design phase, then diagnostic accuracy is improved, but development effort increases
Solution Approach 1:
The patent applies universality by designing the process model to serve multiple functions: it is used both during the design phase for process validation and later in the manufacturing phase for real-time diagnostics. This multi-functional approach allows the same detailed model to improve fault detection accuracy without requiring separate diagnostic model development, thereby reducing overall development effort
Solution Approach 2:
The patent uses preliminary action by completing the detailed process model development during the design phase before production begins. This upfront effort captures all potential failure modes and validates process behavior, allowing the manufacturing phase to reuse the existing model for diagnostics without repeating the detailed modeling work, thus improving accuracy while managing development effort
Data Source
AI summary
A method and apparatus that includes determining differences between a process model and an actual process are used as a diagnostic system for the actual process. The process model includes elements from a design process to provide a “known good” condition for evaluating the differences. Initial input states to the process model are the initial input states to the actual process. Output information correlated to states in the actual process is provided by controls, such as programmable logic controllers, that manage the actual process.