Remote Food Processing Control for Real-Time Event Detection
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Solution Overview
Problem
Conventional food processing systems require physical presence of personnel to monitor and control operations, leading to informational gaps and inefficiencies in identifying and resolving operational issues, which can result in reduced system performance and increased costs.
Innovation Solution
The implementation of an automated monitoring and control system that uses a distributed computing network to remotely monitor and control food processing systems, enabling real-time data collection, event detection, and configuration adjustments through a graphical user interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If personnel are physically present at processing facilities to monitor equipment and processes, then operational monitoring and control can be performed, but information access is limited to local observations and response time to issues is delayed
Solution Approach 1:
The patent introduces a centralized control system that acts as an intermediary between multiple processing systems and operators. This control system collects data from various sources, processes it centrally, and provides comprehensive information to operators, eliminating the need for personnel to be physically present at each facility while maintaining full operational visibility.
Solution Approach 2:
The patent creates virtual copies of processing system data and operational states through digital representations. Sensors and controllers generate digital twins or replicated data streams that allow operators to monitor and control remote systems remotely, providing complete information access without physical presence.
2Productivity
If personnel are assigned to specific divisions to manage operations, then local operational control is maintained, but identification and resolution of cross-system issues becomes slower
Solution Approach 1:
The patent merges previously separate control functions into a unified centralized control system. Multiple processing systems that were independently monitored and controlled are now integrated into a single control platform, allowing operators to view and manage all systems from one location, thereby speeding up problem identification and resolution across the entire facility.
Solution Approach 2:
The patent implements comprehensive feedback loops where sensors continuously monitor system parameters and automatically feed this information back to the control system. When anomalies or issues are detected, the system immediately notifies operators and can even trigger automated responses, dramatically reducing the time required to identify and resolve operational problems.
3Reliability
If conventional monitoring systems are used with local personnel presence, then system operation can be monitored, but operational costs increase and system performance decreases due to informational gaps
Solution Approach 1:
The patent enables processing systems to self-monitor and self-report their operational status through integrated sensors and controllers. The systems automatically detect potential failures, diagnose issues, and communicate problems to the control system without requiring human intervention, thereby improving reliability while reducing the need for automated personnel deployment.
Solution Approach 2:
The patent replaces the mechanical system of physical personnel presence with electronic and computational systems. Digital sensors, networked controllers, and software-based monitoring replace the need for human operators to physically visit facilities, providing continuous reliable monitoring while reducing operational costs and improving safety in caustic environments.
Data Source
AI summary
Systems and methods for automated monitoring and control of food processing systems are disclosed. Data from one or more controllers of a food processing system is received during operation of the food processing system at a remote food processing facility. Values of one or more operating parameters of the food processing system are monitored, based on the received data. At least one event of interest occurring during the operation of the food processing system is detected, based on the monitored values of the one or more operating parameters. Control signals for adjusting a configuration of the food processing system are transmitted to the one or more controllers, based on the detected event.