Sensor Feedback Across Automated Process Stages for Deviation Detection
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Solution Overview
Problem
In industrial automated processes, such as weighing, filling, arranging, and packing, various influencing factors can lead to deviations in sub-processes that negatively impact the overall process quality, making it complex to ensure cargo stability and security, and these deviations often remain unrecognized until downstream processes are affected.
Innovation Solution
A device and system that utilize sensors to detect sub-process parameters, processing devices to assess these data values, and interface devices to forward them across sub-processes, enabling evaluation against pre-defined defaults for improved quality assurance and cargo security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple sub-processes are performed by individual machines in an automated process, then productivity and automation extent are improved, but device complexity and difficulty of detecting deviations increase
Solution Approach 1:
The system segments the automated process into multiple sub-processes, each handled by individual machines with dedicated sensors. This allows each machine to operate independently while maintaining overall process control, resolving the contradiction by enabling high productivity through specialization while managing complexity through modular architecture.
Solution Approach 2:
Sensors in each sub-process provide feedback about process parameters and deviations. This feedback mechanism enables real-time monitoring and control across multiple machines, allowing the system to maintain high productivity while detecting and correcting deviations before they affect overall process quality.
2Ease of operation
If deviations in sub-processes are not monitored, then ease of operation is improved, but reliability and measurement precision deteriorate
Solution Approach 1:
Each sub-process is equipped with sensors that automatically monitor and detect deviations without requiring manual intervention. The system serves itself by autonomously identifying quality issues, maintaining reliability while preserving ease of operation through automated detection rather than manual inspection.
Solution Approach 2:
Manual monitoring and detection methods are replaced with automated sensors and electronic measurement systems. This substitution enables continuous, precise monitoring of process parameters without adding operational complexity, thereby maintaining reliability while preserving ease of operation.
3Measurement precision
If sensors and monitoring systems are added to detect sub-process parameters, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The monitoring system is segmented into individual sensors placed at each sub-process stage. Each sensor monitors specific local parameters, and the overall system achieves high measurement precision through distributed monitoring rather than centralized complex instrumentation, thereby managing device complexity through modular sensor deployment.
4Reliability
If deviations are detected early in sub-processes, then reliability and cargo security are improved, but loss of time for data collection and analysis increases
Solution Approach 1:
Sensors are positioned to detect deviations at the earliest possible stage in each sub-process. By performing preliminary detection before deviations propagate through the system, the patent enables early intervention and correction, improving cargo security while minimizing the time needed for data collection and response.
Data Source
AI summary
The invention relates to a device (10) for at least one industrial automated process (110), in particular a weighing and/or packing and/or arranging and/or packing process, comprising: at least one sensor (30) for determining at least one process data value which is relevant to the entire process by detecting at least one partial process parameter of the device (10), which parameter is relevant to the entire process, a processing device (40), which is electrically connected to the sensor (30) for processing the process data value, an interface device (50) for data connection and for forwarding the process data value to at least one individual machine (2a, 2b, 2c) located upstream and/or downstream in the process (110), wherein the total process (110) can be evaluated with reference to the process data value by comparison with a pre-defined process instruction (130).