Digital Control Plan Twin for Continuous Process Verification
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Solution Overview
Problem
Traditional control plans in manufacturing are limited by their human-readable format, which restricts their use in automation, thereby reducing their value in ensuring quality assurance and process optimization.
Innovation Solution
A digital twin of a control plan is created, allowing for the digital representation, analysis, and optimization of product and process conformity through a digital system model that connects with real-world data from sensors, enabling continuous verification and validation and transforming traditional text-based information into machine-executable models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If control plan is maintained in human-readable format, then ease of operation is improved, but extent of automation deteriorates
Solution Approach 1:
The patent creates a digital twin (copy) of the control plan that exists in both human-readable and machine-executable formats. This digital replica enables automation while the original human-readable version maintains ease of operation for operators. The digital twin captures all control elements, parameters, and logic, allowing automated systems to execute control plan requirements without compromising human readability of the source documentation.
Solution Approach 2:
The patent transforms the control plan from static human-readable text into a dynamic digital model with executable parameters. By changing the format parameters from text-only to structured digital data with executable logic, the system enables automation while preserving the original human-readable version for operator reference. The digital twin maintains parameter equivalence between human and machine representations.
2Extent of automation
If control plan is transformed into machine-executable format, then extent of automation is improved, but ease of operation deteriorates
Solution Approach 1:
The patent segments the control plan information into multiple representations: the original human-readable control plan for operator reference and a separate digital twin for machine execution. This segmentation allows each version to serve its intended purpose independently - the human version maintains ease of operation while the digital version enables automation, eliminating the need to choose one format over the other.
Solution Approach 2:
The digital twin serves multiple functions simultaneously: it acts as an executable control model for automation, a validation reference for quality assurance, and a data source for analytics. The system maintains compatibility with the original human-readable control plan while adding these additional functions, making the overall system more versatile without compromising operator ease of use.
3Manufacturing precision
If verification and validation are performed at set stages, then manufacturing precision is maintained, but productivity deteriorates due to stop/resume cycles
Solution Approach 1:
The patent enables continuous verification and validation by executing the digital twin alongside the physical manufacturing process in real-time. Instead of stopping production at predetermined stages to perform validation, the digital twin continuously processes manufacturing data and validates conformance as production proceeds. This continuous action maintains manufacturing precision while eliminating stop/resume cycles that reduce productivity.
Solution Approach 2:
The system implements continuous feedback loops where the digital twin receives real-time manufacturing data, performs validation, and provides feedback on conformance. This continuous feedback mechanism maintains manufacturing precision by immediately identifying deviations while allowing production to continue uninterrupted, unlike traditional staged validation that requires production stoppages.
4Productivity
If digital twin is used for continuous verification, then productivity is improved, but device complexity increases
Solution Approach 1:
The digital twin is a virtual copy of the control plan that runs in software rather than requiring additional physical hardware. This copying approach enables continuous verification and validation without adding physical device complexity - the digital twin executes on existing computing infrastructure while providing enhanced productivity through continuous monitoring and validation capabilities.
Data Source
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AI summary
A method (300) of developing a product (202) is provided that includes generating (302) a digital system model (DSM) (226) that describes the product and a manufacturing process (214) for the product, and generating (304) a digital twin (DTw) (323) of an instance (234) of a component (230) of the manufacturing process, the DTw including a digital replica (236) of the instance. The method includes receiving (306) attribute data (218) for attributes of process/process characteristics subject to sources of variation that affect product quality. The digital replica is executed (308) with input of the attribute data, and thereby updating the DTw to replicate the instance of the component of the manufacturing process as performed. A data analysis of the manufacturing process is performed (310) based on the DTw as updated, and the manufacturing process is modified (312) based on the data analysis to reduce variability in one or more product characteristics. The DTws of multiple instances may be used to generate (340) further improvement.