Machine Process Monitoring with Synchronized Event Timestamps
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Solution Overview
Problem
High-speed filling machines and related apparatuses face challenges in accurately characterizing machine performance during a single operating cycle, leading to sub-optimal performance, reduced throughput, and increased maintenance costs due to cumbersome root cause analysis and inefficient condition monitoring.
Innovation Solution
A method and system for process monitoring that retrieves and aligns video and audio data with machine control instruction time stamps using a master clock, enabling synchronous monitoring and efficient evaluation of machine control instructions and measurable machine conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed operation is implemented to increase throughput, then productivity increases, but measurement precision of machine performance deteriorates
Solution Approach 1:
The system captures process data (video, audio, sensor signals) and generates time stamps for machine control instructions in advance during machine operation. This preliminary data capture and timestamp generation enables subsequent detailed analysis without slowing down the high-speed production process, resolving the contradiction between maintaining high throughput and achieving precise performance measurement.
Solution Approach 2:
A master clock serves as an intermediary time reference system that synchronizes multiple data sources including video capture, audio recording, and machine control instructions. This intermediary timestamp mechanism allows precise correlation of events from different sources at high speeds without requiring the analysis process to slow down the production line.
2Measurement precision
If detailed process monitoring is implemented to improve measurement precision, then machine performance characterization improves, but device complexity increases
Solution Approach 1:
The system uses a universal master clock that provides time stamps for multiple different data sources (video, audio, sensor signals, machine control instructions) simultaneously. This multi-functional time synchronization approach consolidates what would otherwise require separate complex synchronization systems for each data type, reducing overall device complexity while maintaining high measurement precision.
Solution Approach 2:
The machine control system generates its own time stamps for control instructions automatically during normal operation, without requiring external timing equipment. The video and audio systems also self-generate time stamps based on the master clock. This self-service approach eliminates the need for complex external synchronization hardware while achieving precise multi-source correlation.
3Reliability
If multiple data sources are integrated for comprehensive monitoring, then reliability of condition monitoring improves, but ease of operation deteriorates
Solution Approach 1:
The system merges multiple data sources (video, audio, sensor signals, machine control instructions) into a single synchronized timeline using master clock time stamps. This combination allows operators to view all relevant data from different sources aligned in time, improving reliability of condition monitoring while maintaining ease of operation through unified presentation rather than requiring separate analysis of multiple independent data streams.
Solution Approach 2:
The system adds the time dimension as a common organizing principle for all data sources. By displaying video, audio, sensor data, and control instructions all aligned to the same time stamp reference, the system transforms complex multi-source data into an intuitive temporal sequence that is easy to operate and analyze, while significantly improving monitoring reliability.
Data Source
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Figure 2
Figure 3a~3b
AI summary
A method is disclosed comprising retrieving captured process data comprising video and/or audio data capturing at least part of the execution of events in a machine, retrieving at least a first signal representing a measurable machine condition responsive to the events executed, wherein a first sequence of said machine control instructions is configured to trigger a respective first set of said events for execution thereof, determining first time stamps of the machine control instructions, aligning the first time stamps with second time stamps determined for at least one of; i) times of execution of said first set of events determined from the captured process data; ii) the first signal and associated measurable machine condition retrieved in response to execution of said first set of events, displaying a representation of the first sequence of machine control instructions, associated with the first time stamps, together with an output representation said second time stamps.