Manufacturing Condition Setting System for Dynamic Estimation

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Solution Overview

Problem

Existing manufacturing condition setting systems face challenges in efficiently estimating dynamic conditions due to large numbers of static condition combinations, requiring extensive man-hours, inability to correct knowledge once built, and difficulty in estimating dynamic conditions for inexperienced static condition combinations, especially with qualitative variables and high numbers of static conditions.

Innovation Solution

A system that acquires and accumulates static and dynamic conditions in an experience database when they remain constant, allowing for the building of a knowledge base with high estimation precision, enabling early start of manufacturing services, and allowing for easy deletion and updating of experiences and knowledge items.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If knowledge base is built to estimate dynamic conditions for all combinations of static conditions, then estimation precision is improved, but system building time and man-hours increase significantly

Engineering Contradiction:

Improveestimation precisionVSAvoidsystem building time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs preliminary actions by automatically acquiring and accumulating static and dynamic condition data during the manufacturing process before full knowledge base construction is needed. This allows the system to start with partial knowledge and improve estimation precision progressively without requiring complete pre-building of the knowledge base for all static condition combinations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The knowledge base is designed to be dynamic rather than static, allowing continuous updates and additions as new manufacturing data is accumulated. The system can adapt to new static condition combinations over time, improving estimation precision for previously inexperienced conditions without requiring complete pre-programming of all possible scenarios.

Inventive Principle:

Principle #15Dynamics

2Measurement precision

If knowledge base includes all possible static condition combinations, then estimation precision is improved, but device complexity increases

Engineering Contradiction:

Improveestimation precisionVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system segments the knowledge base into manageable components: static conditions, dynamic conditions, and their associations. Rather than treating all combinations as a single complex structure, the system divides data into discrete accumulable units that can be processed and stored independently, reducing overall system complexity while maintaining comprehensive coverage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs self-service by automatically acquiring manufacturing data and accumulating it in the knowledge base without requiring manual intervention for each data entry. This automated data accumulation process reduces the complexity of knowledge base construction and maintenance while enabling comprehensive coverage of static condition combinations.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If knowledge is built from past experiences, then estimation precision is improved, but ability to correct knowledge is lost

Engineering Contradiction:

Improveestimation precisionVSAvoidknowledge correction ability

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The knowledge base is designed as a dynamic structure that allows continuous updates and corrections. Past manufacturing experiences are accumulated but not fixed; the system can add new data, modify existing entries, and correct errors as they are identified. This dynamic approach maintains estimation precision from accumulated experience while preserving the flexibility to correct knowledge when needed.

Inventive Principle:

Principle #15Dynamics

4Measurement precision

If system accumulates data for all static condition combinations, then estimation precision is improved, but data accumulation time lengthens

Engineering Contradiction:

Improveestimation precisionVSAvoiddata accumulation time

Core Design Contradiction:

Measurement precisionVSDuration of action of stationary object

Solution Approach 1:

The system performs preliminary data accumulation during normal manufacturing operations before full estimation capability is required. By continuously accumulating static and dynamic condition data during production, the system builds the knowledge base in parallel with manufacturing activities, reducing the dedicated time required for data collection while improving estimation precision.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7519446B2Manufacture condition setting system, manufacture condition setting method, control program, and computer-readable record medium recording control program therein

Publication Date: 2009.04.14 OMRON CORP

AI summary

A manufacture condition setting system includes a manufacture state acquisition unit to which static/dynamic conditions and a product quality in the case where the static/dynamic conditions do not change for, at least, a predetermined number of manufactured articles in an ordinary manufacture state are inputted together with reference information, a dynamic condition inference unit which estimates and outputs a corresponding optimal dynamic condition in a case where a combination of the static conditions is an experienced one, and a dynamic condition correction unit which, if necessary, corrects inference knowledge stored by the dynamic condition inference unit, by using information inputted from the manufacture state acquisition unit.