Process State Visualization Using Logical Variable Grouping
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Solution Overview
Problem
Current visualization and evaluation systems for production installations, such as plastic injection molding machines, face difficulties in clearly identifying the cause of problems during operations, as they lack effective grouping and association of process variables with logical criteria, making troubleshooting complex.
Innovation Solution
A method and apparatus that organize process variables into logical groups based on installation regions, process steps, material properties, and environmental conditions, allowing for easier identification of issues by associating variables with predefined criteria, facilitating troubleshooting and visualization of changes across multiple hierarchy levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If process variables are monitored individually without logical grouping, then complete process data is available, but problem diagnosis becomes difficult and time-consuming
Solution Approach 1:
The patent segments process variables into logical groups based on installation regions (e.g., injection unit, closing unit, tool) and process steps (e.g., injection phase, holding pressure phase). This segmentation allows operators to focus on specific groups related to the problem rather than analyzing all process variables individually, thereby improving diagnosis ease while preserving complete information through the structured organization.
2Quantity of substance
If all process variables are visualized without categorization, then comprehensive monitoring is achieved, but operator comprehension and troubleshooting efficiency decrease
Solution Approach 1:
The patent divides the large quantity of process variables into manageable logical groups according to installation regions and process steps. This segmentation maintains comprehensive monitoring of all variables while improving troubleshooting efficiency by allowing operators to systematically examine specific groups rather than being overwhelmed by the total volume of data.
Solution Approach 2:
The patent introduces a new organizational dimension by grouping variables along two axes: installation region (spatial dimension) and process step (temporal/functional dimension). This multi-dimensional organization transforms the flat list of variables into a structured hierarchy, enabling operators to navigate and comprehend the data more efficiently while maintaining complete variable coverage.
3Measurement precision
If process variables are grouped by multiple criteria, then cause identification is improved, but system complexity increases
Solution Approach 1:
The patent applies segmentation by creating logical groups based on installation regions and process steps, which improves cause identification precision without significantly increasing system complexity. The segmentation follows natural operational categories that operators already understand, making the grouping system intuitive rather than complex.
Solution Approach 2:
The patent creates universal logical groups that serve multiple functions: they organize variables for monitoring, facilitate problem diagnosis, and support process optimization. Each logical group is designed to be multi-functional, handling various operational needs without requiring separate complex systems for each function, thereby improving precision while controlling complexity.
Data Source
AI summary
A method for evaluating and/or visualizing a process state of a production system, which contains at least one cyclically operating shaping machine, includes: continuously or at discrete times, determining the value of a plurality of selected process variables, and comparing the current value of each selected process variable and or a variable derived therefrom with one or more reference values by means a computing unit, and determining a deviation or a rate of change. Each selected process variable is assigned to at least one logical group by the computing unit; at least two different logical groups are provided; and for each logical group, a state of the logical group is evaluated by the computing unit based on the process variables assigned to the logical group and/or is visualized by a display device.