Sample Analysis Control Loop for Production-Lab Data Integration
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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, particularly in the transmission of sample identification and control signals, which affects the efficiency and accuracy of the production process.
Innovation Solution
The implementation of connector modules that transmit and receive first type data (sample identifiers) and second type data (control signal data) in a standardized format, allowing for faster and more accurate communication between production and laboratory systems, enabling real-time analysis and control of production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If standardized data communication formats are implemented between production and laboratory systems, then communication speed and accuracy improve, but system complexity increases due to integration requirements
Solution Approach 1:
The patent introduces connector modules as intermediary components that bridge production systems and laboratory systems. These connectors handle data format conversion and protocol translation, enabling standardized communication without requiring complete system reintegration. The connector acts as a mediator that resolves compatibility issues between different systems while maintaining communication efficiency.
Solution Approach 2:
The communication system is segmented into distinct functional modules: production systems, connector modules, and laboratory systems. This segmentation allows each component to be optimized independently while maintaining standardized interfaces. The connector module specifically handles the complexity of integration, separating it from the core production and laboratory functions.
2Reliability
If manual sample identification and tracking are used, then system complexity is reduced, but error rates increase and communication accuracy deteriorates
Solution Approach 1:
The system implements automatic sample identification and tracking where samples are equipped with identifiers (such as barcodes or RFID tags) that are automatically read and processed by the system. The connector modules automatically match sample identifiers with corresponding analysis results without human intervention, eliminating manual errors while maintaining manageable complexity through standardized automated processes.
3Productivity
If real-time data transmission is implemented between production and laboratory systems, then production control speed improves, but data communication errors increase due to protocol mismatches
Solution Approach 1:
The connector modules dynamically adjust communication parameters such as data formats, transmission protocols, and encoding schemes to ensure compatibility between production and laboratory systems. By changing these parameters adaptively, the system achieves real-time communication while maintaining data integrity and avoiding transmission errors caused by protocol mismatches.
Data Source
AI summary
Computer systems 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 provides first type data (A) to identify physical samples, and a manufacturing system provides second type data (B) that are required to control a production process. Connector modules transmit the data (A, B) in a message to a laboratory system to obtain laboratory data, as an analysis result. The connector module that is associated with the laboratory system distributes the data according to the types. A control signal module derives a control signal for controlling the production process. This control signal closes a control loop for adjusting the first sub- process until the laboratory data shows compliance.