Process Monitorer for Real-Time Industrial Defect Detection
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Solution Overview
Problem
In industrial process monitoring, existing systems face challenges in real-time defect identification and maintenance due to large volumes of data, high maintenance costs, and the need for expert knowledge, leading to delayed defect detection and increased operational risks.
Innovation Solution
A process monitoring system comprising a process information acquirer, indexed information generator, threshold acquirer, determination result generator, and notifier, which acquires and analyzes industrial device data in real-time, generates indexed information, determines anomalies based on threshold values, and notifies operators, while also recording and charting data for quick decision-making.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a data collector continuously collects plant information in process-type manufacturing industries, then the amount of information becomes large and comprehensive monitoring is achieved, but it requires constructing a large-scale database which increases maintenance cost and requires expert knowledge
Solution Approach 1:
The patent extracts only the necessary information for defect detection from the continuously collected plant information, rather than storing and analyzing all data. The information management unit selectively manages data based on defect types, extracting only relevant measurement values needed for comparison with reference values, thereby reducing database requirements while maintaining monitoring effectiveness
Solution Approach 2:
The patent segments the monitoring system into distinct functional units: information management unit, defect determination unit, and notification unit. It also segments the analysis by defect type, managing reference values and measurement data separately for different defect types (vibration, temperature, pressure, etc.), which simplifies the overall system architecture and reduces the complexity of the database
2Measurement precision
If analytical experts analyze collected information to identify defect causes, then accurate defect identification is achieved, but it takes a long time and real-time measures cannot be taken
Solution Approach 1:
The system implements self-service defect detection through automated determination. The defect determination unit automatically compares measurement values with reference values stored in the database and identifies defects without requiring expert intervention. The system serves itself by having pre-stored reference values for different defect types that enable automatic comparison and identification, eliminating the time-consuming manual analysis process while maintaining accurate defect detection
Solution Approach 2:
The patent prepares reference values for various defect types in advance and stores them in the database before actual defect detection occurs. These reference values (vibration, temperature, pressure thresholds for different equipment) are pre-configured based on expert knowledge, so when a defect occurs, the system can immediately compare current measurements against these pre-prepared references and quickly identify the defect type without requiring real-time expert analysis
3Ease of operation
If predetermined measurement data is collected to discover device operation defects, then defect signs can be discovered without expert analysis, but the system lacks real-time monitoring capability
Solution Approach 1:
The patent implements continuous monitoring through the information management unit that continuously acquires plant information from multiple sources (measurement devices, control systems). The defect determination unit continuously compares current measurement values with reference values, and the notification unit continuously monitors for defects to be notified. This continuous operation ensures real-time defect detection while maintaining simplicity through automated processes that do not require expert intervention
Data Source
AI summary
The present invention provides a process monitorer, a process monitoring system, a process monitoring method, a process monitoring program, and a recording medium for monitoring processes in real time. The process monitorer including: a process information acquirer for acquiring process information indicating a state of a process provided from an industrial device; an indexed information generator for generating the indexed information indexed by a predetermined index based on the process information; a threshold acquirer for acquiring a threshold of the indexed information; a result of the determination generator for generating the result of the determination of the indexed information based on the threshold; a result of the determination notifier for notifying the result of the determination; an indexed information recorder for recording the indexed information; and a chart generator for generating a chart based on the indexed information.