HMI Alert Indicators for Process Deviation Detection
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Solution Overview
Problem
Operators in industrial settings face challenges in detecting abnormal behavior in complex processes due to the overwhelming number of variables and potential lag in early detection tools, making it time-consuming and inefficient to identify potential issues.
Innovation Solution
A computerized method that displays alert indicators, such as shading, next to values that have exceeded operating limits, along with plots of these values over time, allowing operators to quickly identify parameters that have deviated from normal ranges, with varying intensity based on frequency, extent, and duration of deviation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators manually scan numerical values to detect abnormal behavior, then they can identify process issues, but the task becomes time-consuming and inefficient due to the large number of variables
Solution Approach 1:
The patent replaces the manual mechanical scanning process with an automated computer-based system that uses algorithms to detect abnormal behavior. The system automatically compares process values against historical data and detects deviations, eliminating the need for operators to manually scan numerous variables while improving both detection accuracy and reducing time consumption.
Solution Approach 2:
The system enables self-service by automatically monitoring and detecting abnormal process behavior without requiring continuous operator intervention. The automated detection system serves itself by continuously analyzing process data and generating alerts, allowing operators to focus on response rather than detection.
2Reliability
If traditional trending tools are used to detect early signs of process upsets, then some abnormalities can be identified, but variables may still be missed and there is a slight lag in detection
Solution Approach 1:
The patent implements a universal detection system that can monitor multiple process variables simultaneously using the same automated algorithm. This multi-functional approach ensures comprehensive coverage of all process parameters, preventing missed variables while maintaining early detection capability across the entire process control system.
Solution Approach 2:
The system performs preliminary action by continuously analyzing process data in real-time and comparing it against historical patterns before significant upsets occur. This proactive approach detects early signs of abnormal behavior across all variables simultaneously, providing advance warning without lag and ensuring no variables are missed.
3Reliability
If operators monitor multiple process parameters simultaneously, then comprehensive process oversight is achieved, but the complexity of information processing increases
Solution Approach 1:
The patent extracts and highlights only the critical information - specifically, variables that exhibit abnormal behavior or deviations from normal patterns. Instead of presenting all raw data, the system isolates and presents only the relevant anomalies, reducing information processing complexity while maintaining complete process monitoring capability.
Solution Approach 2:
The system applies local quality by providing detailed analysis and alerting specifically for abnormal variables while maintaining a simplified overall view. When anomalies are detected, the system focuses computational and display resources on those specific local areas of concern, rather than uniformly processing all variables with the same complexity.
Data Source
AI summary
Computerized methods and software for communicating behavior of industrial systems to operators, for instance, in HMI environments. Various embodiments display values of different parameters of the system and an alert indicator for values that passed an operating limit established for the parameter during a particular preceding duration of time. In some embodiments, different indicators (e.g., shading, for example, adjacent to the value) are displayed for exceeding an upper operating limit or a lower operating limit (or both). In a number of embodiments, a plot is displayed for value that has passed an operating limit during the preceding duration of time, for instance, when the operator hovers a cursor over the value. In many embodiments, the operator can set the preceding duration of time, the operating limit(s), or both. In many embodiments, abnormal movements or process variability can be detected by the operator, for example, before the movements would otherwise be detectable.