Noise-Component Extracting Unit for Manufacturing Signal Control
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Solution Overview
Problem
Existing control systems for manufacturing machines struggle to accurately detect failures due to environmental-factor noise, such as vibrations and power fluctuations, which are commonly present in signals collected from robots connected via communication networks.
Innovation Solution
A control device with a receiving unit, a noise-component extracting unit that identifies common noise components in signals from multiple manufacturing machines, and a noise-component removing unit that filters out these noise components, allowing for precise abnormality detection and improved control accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a filter is applied to remove environmental-factor noise from sensor signals, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent segments the noise removal process into three distinct functional units: a receiving unit that collects signals from multiple manufacturing machines, a noise-component extracting unit that identifies common noise patterns across signals, and a noise-component removing unit that subtracts the extracted noise from individual signals. This segmentation allows each unit to perform a specific function efficiently, improving measurement precision while managing complexity through modular design.
Solution Approach 2:
The patent merges signals from multiple manufacturing machines to identify common noise components. By combining multiple signals and extracting their common characteristics, the system can distinguish environmental noise from actual machine conditions. This merging approach enables more accurate noise removal than processing single signals in isolation, as the common components across multiple signals represent environmental factors affecting all machines.
2Productivity
If information is collected from multiple manufacturing machines via communication network, then productivity improves, but reliability deteriorates due to environmental-factor noise
Solution Approach 1:
The patent extracts the harmful environmental-factor noise from the collected signals through the noise-component extracting unit. This extracted noise component is then removed from individual machine signals, allowing the system to maintain high productivity through comprehensive multi-machine monitoring while improving reliability by eliminating the noise that would otherwise cause false failure predictions.
Solution Approach 2:
The patent converts the harmful environmental noise into a beneficial element by using it as a reference for noise removal. The common noise components extracted from multiple signals serve as a template that is then subtracted from individual signals, transforming the previously harmful noise into a useful tool for improving detection accuracy. This approach allows the system to maintain high productivity from multi-machine data collection while converting the reliability-deteriorating noise into a reliability-enhancing feature.
Data Source
AI summary
A control device includes a receiving unit that receives output signals from a plurality of manufacturing machines, via a communication network; a noise-component extracting unit that extracts a common noise component that is contained in the output signals; and a noise-component removing unit that removes the extracted noise component from at least one of the output signals.