Industrial Process Parameter Tuning for Material Variability
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Solution Overview
Problem
Industrial processes face challenges in adapting to changes in material availability and composition, as existing methods require specific conditions and are difficult to modify, leading to inefficiencies and potential system downtime due to the complexity of modeling and simulating parameter modifications.
Innovation Solution
A computer-implemented method that identifies operation parameters for modification using a simulator module, variator module, and evaluator module to classify and cluster simulation instances, allowing the industrial system to operate with alternative materials while maintaining product quality by adjusting operation parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the industrial system uses specialized components and pre-defined processes, then the manufacturing precision and product quality are maintained, but the adaptability to changes in material availability and composition deteriorates
Solution Approach 1:
The patent implements dynamic adaptability by enabling the industrial control system to dynamically adjust operation parameters based on detected material variations. The system transitions from static pre-defined processes to dynamic parameter modification, allowing the same specialized system to adapt to different material compositions while maintaining product quality standards.
Solution Approach 2:
The core invention involves changing operation parameters in response to material changes. The system detects variations in material properties and automatically modifies process parameters (such as temperature, pressure, flow rates) to compensate for these changes, thereby maintaining manufacturing precision without requiring physical reconfiguration of specialized components.
2Adaptability or versatility
If the system operators modify the industrial process by re-designing system components, then the adaptability to alternative materials is improved, but the device complexity and implementation time increase
Solution Approach 1:
The patent avoids physical re-design by focusing on parameter modifications within the existing system architecture. The control system adjusts operation parameters through software-based adaptations rather than hardware reconfiguration, significantly reducing complexity while maintaining adaptability to alternative materials.
Solution Approach 2:
The system uses digital models and simulations to predict the effects of material changes and determine appropriate parameter adjustments. By creating virtual representations of the process and testing parameter modifications in simulation before implementation, the system avoids complex trial-and-error physical modifications.
3Adaptability or versatility
If the system operators modify the industrial process by adapting control methods, then the adaptability to material changes is improved, but the loss of time for implementation increases
Solution Approach 1:
The system performs preliminary actions by pre-configuring the control architecture to accept and respond to material variations. The system is prepared in advance with the capability to detect material changes and automatically adjust parameters, eliminating the need for time-consuming modifications when actual material changes occur during operation.
Solution Approach 2:
The patent implements real-time feedback mechanisms that continuously monitor material properties and automatically adjust operation parameters in response. This closed-loop control system eliminates delays by immediately detecting material changes and implementing corrective parameter adjustments without human intervention or lengthy analysis periods.
4Manufacturing precision
If the industrial system maintains narrow tolerances to changing conditions, then the manufacturing precision is maintained, but the productivity decreases due to system downtime
Solution Approach 1:
The system dynamically modifies operation parameters in response to material variations, allowing it to maintain product quality compliance even when operating outside traditional tolerance ranges. This enables continuous operation with varying material inputs without shutting down to reconfigure the system, thereby maintaining both precision and productivity.
Solution Approach 2:
The patent transforms the system from a static configuration with fixed tolerances to a dynamic system that continuously adapts parameters to maintain quality. This dynamic approach allows the system to handle material variations in real-time without downtime, preserving both manufacturing precision and continuous productivity.
Data Source
AI summary
A computer-implemented method identifies an operation parameter of an industrial process as a candidate for modification so that the process can continue even of the material at the input of the process changes. In simulation instances, the computer receives representations of the material and of operation parameters and provides a representation of the would-be product. The computer classifies the instances into first and second quality classes. The computer continues by clustering—separated by parameters—the instances according to parameter attributes and according to the first and second quality classes. The computer repeats the simulation with variations that are related to significant differences, and identifies the candidate for modification.