Process Indicator Assessment for In-Operation System Condition
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Solution Overview
Problem
Conventional system diagnostics fail to provide a fast and simple assessment of the current condition of a system in operation, lacking efficient methods for condition monitoring and fault diagnosis.
Innovation Solution
A method and device that acquire data on faults, process time, and media/energy consumption to calculate a process indicator number, which indicates the system's condition, enabling automatic decision-making for maintenance and troubleshooting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional system diagnostics are used, then the system can operate continuously, but the assessment of current system condition is slow and complex
Solution Approach 1:
The system segments the overall system condition assessment into three distinct data categories (fault data, process time data, media and energy consumption data), each contributing to specific segments of the process indicator number. This segmentation allows for targeted data collection and simplified analysis of each component separately while maintaining comprehensive system monitoring.
Solution Approach 2:
The process indicator number serves as an intermediary metric that translates complex multi-dimensional system data into a single comprehensible value. This intermediary enables rapid system condition assessment without requiring direct analysis of the underlying complex data structures, thus speeding up diagnostics while managing complexity.
2Measurement precision
If comprehensive data collection is implemented, then system condition assessment becomes more accurate, but data processing complexity increases
Solution Approach 1:
The system transforms diverse physical quantities (fault frequencies, process times, media consumption, energy consumption) into a unified dimensionless process indicator number scaled from 0 to 100. This parameter transformation enables precise system condition assessment through standardized metrics while simplifying the processing of heterogeneous data through consistent normalization and weighting schemes.
3Reliability
If continuous monitoring is performed, then system condition detection is improved, but energy and resource consumption increases
Solution Approach 1:
The monitoring system utilizes existing multi-functional sensors and data acquisition infrastructure already present in the process system, rather than adding dedicated monitoring equipment. The process indicator number calculation repurposes routinely collected process data (fault records, process times, media and energy consumption) for diagnostic purposes, thereby improving fault detection reliability without significantly increasing energy consumption or resource usage.
Data Source
AI summary
A method for automatically determining a current condition of a system in operation includes acquiring first data relating to one or more faults in the system during a process, acquiring second data relating to a process time in the system during the process, acquiring third data relating to media and energy consumption in the system during the process, and determining a process indicator number based on the first, second, and third data. A device for automatically determining a current condition of a system in operation is configured to carry out the method.