Production Line State Inference for Unmonitored Components
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Solution Overview
Problem
Existing systems lack interfaces for the automatic acquisition of data from individual system components in production lines, particularly in linked processes like SMT manufacturing, leading to inefficiencies and lower Overall Equipment Effectiveness (OEE) due to undetected malfunctions.
Innovation Solution
A method and system that utilizes state detection devices on adjacent components to infer the condition of components without direct monitoring, analyzing log entries and comparing states to determine the condition of unmonitored components, enabling continuous monitoring and automated response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If state detection devices are installed on all system components, then monitoring reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses upstream and downstream components as intermediaries to indirectly monitor the state of the target component. Instead of installing detection devices directly on conveyor belts or simple components, the system infers their state from the operational data of adjacent components that are already equipped with detection devices. This mediator approach allows monitoring of components without direct sensors.
Solution Approach 2:
The state detection devices on upstream and downstream components serve multiple functions: they monitor their own component states and simultaneously provide data to infer the states of adjacent components. This multi-functionality eliminates the need for separate dedicated detection devices for each component, reducing overall system complexity while maintaining comprehensive monitoring coverage.
2Productivity
If traditional manual monitoring methods are used, then implementation simplicity is maintained, but productivity and response time deteriorate
Solution Approach 1:
The system continuously collects operational data from state detection devices, processes this information through evaluation logic, and automatically generates feedback regarding component states. This closed-loop feedback mechanism enables real-time monitoring and automatic identification of malfunctions, significantly improving productivity compared to manual methods while maintaining reasonable automation levels.
Solution Approach 2:
The monitoring system performs self-service by automatically collecting, processing, and evaluating data without requiring manual intervention. The evaluation logic autonomously determines component states and identifies issues, eliminating the need for manual fault matrix filling and expert assessment, thereby boosting productivity.
3Measurement precision
If simple components like conveyor belts are monitored manually, then implementation cost is reduced, but measurement precision and response time worsen
Solution Approach 1:
Instead of installing detection devices on every single component (excessive action), the system strategically places detection devices on key upstream and downstream components and uses logical inference to determine the states of intermediate simple components. This partial monitoring approach achieves sufficient measurement precision while avoiding the information loss that would occur with purely manual methods.
Data Source
AI summary
The invention relates to a method for determining a first system state (14) of a first system component (16) of a production plant (10) with at least three linked system components (16, 18, 20), comprising the steps of: providing a second system component (18) with a second state detection device (22) and a downstream third system component (18) with a third state detection device (24), wherein at least one first system component (16) is provided between the second system component (18) and the third system component (20), wherein the first system component (16) is provided without a state detection device; detecting a second system state (26) of the second system component (18) by means of the second state detection device (22) and detecting a third system state (28) of the third system component (20) by means of the third state detection device (24);and determining the first system state (14) of the first system component (16) as a function of the second system state (26) and the third system state (28) by means of an electronic computing device (12). Furthermore, the invention relates to a computer program product, a computer-readable storage medium, an electronic computing device (12) and a manufacturing plant (10).