Process State Visualization With Hierarchical Variable Grouping
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Solution Overview
Problem
Current visualization and evaluation systems for production plants, such as plastic injection molding machines, face difficulties in identifying the cause of problems due to the complexity of process variables and lack of effective grouping mechanisms.
Innovation Solution
A method and device that assigns process variables to logical groups based on criteria like system areas, process steps, and physical variables, allowing for easier troubleshooting by visualizing and assessing changes within these groups, enabling operators to understand the root cause of issues more effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If process variables are monitored individually without grouping, then comprehensive monitoring coverage is achieved, but problem cause identification becomes difficult
Solution Approach 1:
The patent divides the complex set of process variables into hierarchical logical groups (first-level groups like 'injection unit', 'molding tool'; second-level groups like 'injection phase', 'holding pressure phase'). This segmentation allows operators to navigate from general to specific variables systematically, resolving the contradiction by making the visualization structure manageable while maintaining comprehensive monitoring coverage.
Solution Approach 2:
The patent introduces a hierarchical dimension to the visualization structure, organizing variables across multiple levels (first-level logical groups containing second-level logical groups containing individual variables). This dimensional organization transforms the flat complex set into a structured hierarchy, enabling efficient problem cause identification without overwhelming the operator with complexity.
2Loss of information
If all process variables are displayed in detail, then complete information is provided, but operator understanding and troubleshooting efficiency decrease
Solution Approach 1:
By segmenting variables into hierarchical logical groups, the patent allows operators to focus on specific groups relevant to the problem at hand rather than viewing all variables simultaneously. This maintains information completeness while improving troubleshooting efficiency through selective focus.
Solution Approach 2:
The patent applies local quality by allowing different levels of detail to be displayed in different parts of the interface. Operators can view summary information at higher levels and drill down to detailed variable information at lower levels, providing appropriate detail quality for each operational context.
3Ease of operation
If process variables are grouped by multiple criteria, then better organization is achieved, but assignment complexity increases
Solution Approach 1:
The patent segments the organization task by applying multiple grouping criteria at different hierarchical levels. First-level groups are formed by functional units (injection unit, molding tool), while second-level groups are formed by process phases (injection phase, holding pressure phase). This segmented approach achieves better organization while managing assignment complexity through systematic categorization.
Solution Approach 2:
The patent adds hierarchical dimension to the grouping structure, organizing variables first by functional unit, then by process phase, then by individual variable. This multi-dimensional organization achieves superior variable organization while the systematic hierarchical approach keeps the assignment mechanism manageable.
Data Source
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AI summary
The invention relates to a method for evaluating and/or visualizing a process state of a production system (1), which contains at least one cyclically operating shaping machine (2), wherein: continuously or at discrete times, the value of a plurality of selected process variables is determined and the current value of each selected process variable and or a variable derived therefrom is compared with one or more reference values by means of a computing unit (4) and a deviation or a rate of change is determined; each selected process variable is assigned to at least one logical group by means of the computing unit (4); at least two different logical groups are provided; and for each logical group, a state of the logical group is evaluated by means of the computing unit (4) on the basis of the process variables assigned to said logical group and/or is visualized by means of a display device (5).