Production Line Visualization Using Hierarchical Process Groups
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Solution Overview
Problem
Current visualization and assessment devices for production systems, such as plastic injection molding machines, face difficulties in identifying the root cause of problems due to the complexity of process variables and the lack of effective grouping and comparison methods.
Innovation Solution
A visualization and assessment device that organizes process variables into logical groups at multiple hierarchical levels, allowing for easier identification of deviations and changes by comparing selected process variables with reference values, and providing a hierarchical structure for better error correction and process optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If process variables are monitored individually without grouping, then comprehensive monitoring coverage is achieved, but cause analysis becomes difficult and operator understanding is reduced
Solution Approach 1:
The patent divides the production plant's process variables into multiple logical groups (e.g., injection unit, clamping unit, mold, material supply) that reflect the physical structure and functional relationships of the system. This segmentation allows operators to understand causes by identifying which logical group contains the deviation, making cause analysis straightforward while maintaining comprehensive monitoring coverage.
Solution Approach 2:
The patent introduces a hierarchical dimension to the visualization structure, organizing logical groups in at least two hierarchy levels where higher-level groups contain lower-level groups. This dimensional organization enables operators to navigate from general to specific causes systematically, improving cause analysis without overwhelming complexity.
2Ease of operation
If all process variables are visualized in detail, then complete process information is provided, but operator comprehension and error identification become difficult
Solution Approach 1:
By segmenting process variables into logical groups corresponding to physical units and functional areas, the patent enables operators to identify errors by locating which group is affected rather than searching through all individual variables. This maintains access to complete process information while making error identification practical.
Solution Approach 2:
The hierarchical organization adds a structural dimension to variable visualization, allowing operators to drill down from group level to individual variable level as needed. This enables comprehensive information access while maintaining ease of operation through progressive disclosure.
Data Source
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AI summary
Visualization device for a production plant (1) comprising at least one cyclically operating forming machine (2) for visualizing a process state of the production plant (1) with: - a display device (5) for displaying a visualization program stored in a storage medium (6) - a computing unit (4) which is in a data-transmitting connection with the display device and/or the storage medium or is configured to be brought into a data-transmitting connection with the display device (5) and/or the storage medium (6) and which is configured toto determine the value of a plurality of selected process variables of the production plant (1) continuously or discretely over time and to compare the current value of each selected process variable or a variable derived therefrom with one or more reference values and to determine a deviation or a rate of change, wherein it is preferably provided that the visualization program is configured to visualize each selected process variable with respect to its value and/or the deviations or rates of change determined by the computing unit (4) by means of the display device (5), wherein different logical groups can be visualized by means of the visualization program and that each selected process variable is assigned to at least one of the logical groups and that for each logical group a state of the logical group based on the process variables assigned to this logical group can be visualized by means of the display device (5).