Manufacturing Data Correlation Using Precision Counter Matching
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Solution Overview
Problem
Current manufacturing systems lack the capability to transmit and receive continuous, high-frequency data streams in real-time, making real-time monitoring and control of programmable machines impossible, and previous systems collected data separately without connections for analytics, limiting geospatial and process data integration.
Innovation Solution
A method involving a high precision counter to associate real-time and non-real-time data from automation systems, allowing for contextual linking and storage in a buffer, followed by processing and visualization using 3D and 2D data integration for advanced analytics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If data is collected separately without connection to one another, then data collection is simpler, but analytics capability is limited due to lack of integration between geospatial points, process values, and instructions
Solution Approach 1:
The patent combines previously separate data streams (geospatial points, process values, and NC instructions) into a unified data structure by associating them through counter values. This merging enables comprehensive analytics while maintaining manageable system complexity through standardized association mechanisms.
Solution Approach 2:
The patent introduces counter values as intermediary elements that link different data types together. These counters serve as mediators that associate geospatial points, process values, and instructions without requiring direct complex interconnections between all data elements, thus enabling integration while controlling system complexity.
2Reliability
If real-time data streaming is implemented, then monitoring capability is improved, but machine compatibility is reduced because many programmable machines are not equipped to transmit continuous high-frequency data streams
Solution Approach 1:
The patent associates data with counter values at the point of collection before transmission. This preliminary association ensures that when data is received, the temporal and contextual relationships are already established, enabling real-time monitoring capabilities without requiring the source machines to have advanced data streaming infrastructure.
Solution Approach 2:
The counter value mechanism serves multiple functions: it timestamps data, sequences events, and provides a common reference for associating different data types. This universal approach enables real-time monitoring across diverse machine types without requiring machine-specific implementations.
3Quantity of substance
If tracing durations are limited to short durations, then data storage requirements are reduced, but diagnostic capability is limited for analyzing longer-term manufacturing issues
Solution Approach 1:
The patent segments data into discrete units associated with counter values, allowing selective storage and retrieval of specific time periods or event ranges. This segmentation enables efficient storage by only retaining relevant data segments while maintaining the ability to reconstruct longer diagnostic timelines when needed.
Data Source
AI summary
Techniques are described for receiving manufacturing data and events over real time and non-real time interfaces and associating the data with one another. In one example, real time data is received, the real time data associated with a counter value assigned by a precision counter. The received real time data is stored in a storage buffer, and non-real time data is received, where the non-real time data associated with a counter value assigned by the precision counter. In response to receiving the non-real time data, the buffer is searched for real time data having a matching counter value and, in response to identifying stored real time data associated with a matching counter value, the non-real time data is associated with the real time data based on the match. Data packages are generated including related real time and non-real time data associated with matching counter values.