Process Control System for Dynamic Manufacturing Parameter Adjustment

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Solution Overview

Problem

Conventional manufacturing systems are inflexible and require specific starting materials, limiting product diversity and requiring skilled operators, as they do not allow for dynamic adjustment of manufacturing processes and lack reliable quality control.

Innovation Solution

A process control system that determines current product parameters using sensors like 3D laser scanning, applies transformation matrices to select compatible process actions, and dynamically updates available actions based on usage probabilities, enabling flexible and accurate production of diverse products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional manufacturing systems use fixed default starting pieces, then the manufacturing process is simple and controlled, but the system lacks flexibility and cannot handle diverse starting materials

Engineering Contradiction:

Improveflexibility to handle diverse starting materialsVSAvoidcomplexity of manufacturing process control

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system dynamically adapts the manufacturing process based on the actual starting material detected. Sensors scan the workpiece to determine its geometry and properties, then the control system automatically adjusts the manufacturing instructions in real-time, transforming a static fixed-process system into a dynamic adaptive one

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes manufacturing parameters (dimensions, tolerances, processing steps) based on the detected starting material characteristics. The n-tuple representation allows flexible parameter adjustment without requiring fixed predefined specifications

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If operators manually check work piece correctness at every step, then manufacturing accuracy is ensured, but the process is time-consuming and requires skilled operators

Engineering Contradiction:

Improveaccuracy of work piece verificationVSAvoidtime for manual inspection

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system implements automated feedback loops where sensors continuously monitor the workpiece after each manufacturing step, compare actual results with target specifications, and automatically adjust subsequent operations. This replaces manual inspection with automated real-time feedback control

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual operator inspection is replaced with automated sensor systems (optical, tactile, or other detection mechanisms) that objectively measure workpiece properties and provide digital feedback to the control system, eliminating human subjectivity and time consumption

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the system provides comprehensive training and help services, then new users can effectively operate the manufacturing system, but the solution is expensive and time-consuming

Engineering Contradiction:

Improveusability for new usersVSAvoidtraining time and setup time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system provides self-service through automated guidance interfaces that contextually guide operators through manufacturing steps, automatically suggest appropriate parameters, and provide real-time assistance based on the current workpiece state, eliminating the need for extensive external training

Inventive Principle:

Principle #25Self-service

4Adaptability or versatility

If manufacturers restrict users to pre-defined boundaries, then the system remains simple and controlled, but users cannot implement features beyond system capabilities

Engineering Contradiction:

Improveability to implement custom featuresVSAvoidcomplexity of system configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system achieves universality by providing a standardized n-tuple interface and transformation matrix framework that can represent and execute any manufacturing operation. This modular architecture allows the system to handle both standard and custom features through a unified flexible platform

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10114362B2Method and system for controlling the production process of a product

Publication Date: 2018.10.30 LANGER CHRISTOPH

AI summary

A method for controlling production processes of products. A first n-tuple representative of current parameters of product are determined and stored. The current parameters are displayed. Control elements are displayed for selecting from pre-defined process actions compatible for performing on product having the current parameters retained in the first n-tuple. Each process action is representative of a first transformation matrix of dimension compatible with the first n-tuple. The pre-defined process actions and associated first transformation matrices are stored. A process action is selected from the pre-defined process actions. The first transformation matrix corresponding to the selected process action is applied to the first n-tuple to produce a second n-tuple of future product parameters. The product having the future parameters of the second n-tuple is displayed. Instructions are provided representative of the matrix elements in the first transformation matrix performing a process step on the product corresponding to the process action.