Production-Lab Data Connectors for Closed-Loop Chemical Control
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Solution Overview
Problem
The communication between computer systems at production and laboratory sites in the chemical industry is hindered by differences in data conventions, leading to delays and errors in sample identification and production control, particularly due to the need for human intervention and the complexity of data exchange across systems.
Innovation Solution
The implementation of connector modules that transmit and receive data types A and B, enabling efficient communication between production and laboratory systems, allowing for immediate analysis preparation and reduced delay by forwarding data instead of physical samples, and using predefined templates and secure protocols like HTTPS.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical samples are forwarded from production site to laboratory site for analysis, then accurate material identification and analysis can be performed, but communication delays and human intervention errors occur
Solution Approach 1:
The patent creates digital copies of sample data and metadata that can be transmitted electronically between systems. Instead of relying solely on physical sample transport, the system generates and transmits digital representations of sample information, allowing parallel processing and reducing waiting time while maintaining identification accuracy through consistent data representation.
Solution Approach 2:
The patent introduces an intermediary data exchange system that facilitates communication between production and laboratory computer systems. This intermediary layer uses standardized data formats and protocols to enable seamless information transfer, eliminating the need for manual data re-entry and reducing communication delays while maintaining data integrity.
2Adaptability or versatility
If human operators manually handle sample identification and data transfer between systems, then flexibility and adaptability are maintained, but errors and delays increase
Solution Approach 1:
The patent enables computer systems to automatically perform data exchange and sample tracking functions without human intervention. The systems self-manage data transmission, sample identification, and result communication through automated protocols, eliminating manual errors while maintaining operational flexibility through programmable workflows that can be adjusted as needed.
Solution Approach 2:
The patent replaces manual mechanical operations with automated computer-based systems. Physical handling of sample documentation and manual data entry are substituted with electronic data transmission and automated processing, significantly reducing human error while maintaining the ability to adapt through software configuration.
3Productivity
If multiple computer systems with different data conventions interact, then comprehensive production control is achieved, but communication complexity and data exchange obstacles increase
Solution Approach 1:
The patent implements a universal data exchange framework that can accommodate multiple different data conventions and formats. The system uses standardized intermediate formats and translation layers that enable diverse computer systems to communicate effectively, allowing comprehensive production control across multiple systems without requiring each system to be redesigned for every interaction.
4Productivity
If data is transmitted in advance to prepare for analysis, then analysis time is reduced, but data communication obstacles may occur
Solution Approach 1:
The patent enables advance transmission of sample data and metadata to the laboratory system while the physical sample is still being prepared or transported. This preliminary data transmission allows the laboratory system to prepare analysis protocols and configure instruments in advance, reducing overall analysis time. The use of standardized data formats ensures reliable communication even during advance transmission.
Data Source
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AI summary
Computer systems (130, 120, 230) support a production process with a first sub-process to process a chemical substance at a production site and with a second sub-process to analyze a physical sample of the chemical substance at a laboratory site. A process control system (120) provides first type data (A) to identify physical samples, and a manufacturing system (130) provides second type data (B) that are required to control a production process. Connector modules (105, 205) transmit the data (A, B) in a message (150) to a laboratory system (230) to obtain laboratory data, as an analysis result. The connector module (205) that is associated with the laboratory system (230) distributes the data according to the types. A control signal module (139) derives a control signal (136/138) for controlling the production process. This control signal closes a control loop for adjusting the first sub- process until the laboratory data shows compliance.