Multi-Variable Process Control Using Phase-Specific Operational Envelopes
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Solution Overview
Problem
Existing methods for controlling multi-variable processes in industrial operations are limited in applicability, particularly in multi-phase processes, as they require separate modeling and control of each phase, which is time-consuming and may not ensure consistent objectives across the entire process.
Innovation Solution
A method and system that accumulate historical data from multiple operations across all phases to establish operational envelopes, allowing for consistent modeling and control of multi-variable processes by indicating current values on multi-dimensional displays and adjusting process variables within defined bounds to maintain operational feasibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate modeling and control of each phase is implemented, then control precision for each phase is improved, but device complexity and time required for setup and maintenance increase
Solution Approach 1:
The patent divides the multi-phase process into distinct phases, with each phase having its own operational envelope derived from historical data. This segmentation allows precise control for each phase while automatically managing the complexity through systematic data accumulation and envelope calculation methods.
Solution Approach 2:
The system performs preliminary actions by accumulating historical process and quality variable data across multiple operations and phases before control is needed. Operational envelopes are pre-calculated from this historical record, so when control is required, the bounds are already established and ready for immediate use.
2Manufacturing precision
If separate modeling and control of each phase is implemented, then control precision for each phase is improved, but time required for setup and maintenance increases
Solution Approach 1:
The system maintains continuous accumulation of historical data across all phases and operations. This continuous data gathering means that operational envelopes are progressively refined over time without requiring periodic interruptions for setup or recalibration, thereby reducing maintenance time while maintaining precision.
3Manufacturing precision
If separate modeling of each phase is performed, then phase-specific control is improved, but adaptability across the entire process decreases
Solution Approach 1:
The patent creates a universal framework where the same operational envelope methodology is applied across all phases of the multi-phase process. Each phase has its own envelope, but they are all derived using the same systematic approach from historical data, ensuring consistency and adaptability across the entire process while maintaining phase-specific precision.
Data Source
AI summary
A control of a multi-variable process throughout a plurality of successive, distinct operational phases of the process involves accumulation of sets of values of the process and quality variables (a-j) from previous multiple operations of the process through all its phases, as respective datasets of a historical record. Each dataset includes an identifier (p) of the phase to which it relates. The current values of the applicable process variables (Qa-Qh) during each phase and the phase identifier (p) are indicated on respective axes (Xp,Xa-Xh) of a multi-dimensional display in relation to an operational envelope which defines bounds (UL,LL) for the values of the individual process and quality variables (a-j) relevant to that phase and which is derived from the datasets of the historical record identified with that phase. Changes in the current process variables (Qa-Qh) result in changes of the bounds (UL,LL), and alarm is given when a current value departs from within them. Either manually or automatically correction of an alarm condition is made in accordance with calculation of required change of value of one or more manipulatable process variables (a-c).