Production Control Risk Switching for Automated Manufacturing
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Solution Overview
Problem
Highly automated production processes often lack mechanisms to assess and mitigate risks, leading to the production of non-usable products due to ignored risks, as human operators may not be available to intervene effectively.
Innovation Solution
A control system that determines actual risk values for products and components, using these values to adjust process control data automatically, switching processing modes to minimize risk without human intervention, by integrating risk evaluation and control units with production equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high degree of automation is implemented in production processes, then productivity and efficiency are improved, but the ability to assess and respond to risks is reduced
Solution Approach 1:
The control system automatically performs risk assessments and adjusts process parameters without human intervention. The system monitors process data, evaluates risks using predefined criteria, and autonomously modifies control parameters to mitigate identified risks, enabling the automated production system to self-regulate safety and quality
Solution Approach 2:
The system continuously monitors process data and feeds this information back to the risk evaluation module. Based on the feedback loop, the system dynamically adjusts control parameters in response to changing risk conditions, creating a closed-loop control mechanism that maintains reliability in highly automated processes
2Device complexity
If human operators are reduced or eliminated from production lines, then labor costs and operational complexity are reduced, but the ability to intervene in response to risks is lost
Solution Approach 1:
The patent replaces human operators with an automated control system that uses software algorithms and computational models to perform risk assessment and decision-making functions. The control system substitutes human cognitive processes with automated data analysis and rule-based reasoning mechanisms
Solution Approach 2:
The control system acts as an intermediary between production equipment and risk management functions. It mediates between automated production processes and safety/quality requirements by continuously evaluating risks and adjusting parameters, serving as a bridge that enables automated operation while maintaining risk control
3Reliability
If risk assessment mechanisms are added to automated production systems, then reliability and product quality are improved, but system complexity and computational requirements increase
Solution Approach 1:
The risk assessment functionality is divided into modular components that can be independently configured and managed. The control system separates risk evaluation, analysis, and mitigation functions into distinct modules, allowing for targeted implementation of risk management capabilities without overwhelming system complexity
Solution Approach 2:
The system manages complexity by dynamically adjusting control parameters based on risk levels rather than fundamentally changing system architecture. When risks are identified, the control system modifies existing process parameters within predefined ranges, avoiding the need for complex structural modifications while maintaining product quality
Data Source
AI summary
A control system (100) and control method for controlling a process performed by production equipment (200). The control system has a first interface (191) configured to obtain, from a data provisioning module (310), production control data (311) for operating the production equipment (200) wherein the production control data (311) relates to operating instructions configured to control the production equipment (200) to automatically process a plurality of physical items (I1, I2) and their respective components (C1 to Cn). It further includes a risk evaluator module (110) configured to determine for each item a total risk value based on partial risk values associated with the respective components (C1 to Cn), and further configured to detect a change in the determined total risk values. It further includes a control unit (120) configured to: initiate, via a second interface (192), execution of the operating instructions for manufacturing a particular item (I1) having the lowest total risk value during a first operating time interval (OTV1); initiate termination of the execution of the operating instructions for processing the particular item (I1) if the change in the determined total risk values results in an alternative item (I2) having the lowest total risk value; and initiate, via the second interface (192), execution of the operating instructions for processing the alternative item (I2) during a second operating time interval (OTV2).