Sequential Process Analysis via Phase Limits and Subprocess Detection
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Solution Overview
Problem
Existing methods for optimizing sequential processes, such as production or logistics, face challenges in accessing control units to analyze process data, particularly for cyclical or noncyclical processes, as they often require manufacturer access and do not allow for automated division into subprocesses to assess stability and quality.
Innovation Solution
A method that records process data over a reference time period, determines phase limits, identifies repeating subprocesses, and compares data to reference variables to establish deviations from normal operation, enabling automated division and analysis of sequential processes without direct access to control units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If access to control units is required to analyze process data, then measurement precision is improved, but device complexity and ease of operation deteriorate due to manufacturer restrictions and additional costs
Solution Approach 1:
The patent introduces an intermediary analysis device that connects to machines via non-intrusive load monitoring (NILM) techniques. This intermediary captures aggregate power consumption data without requiring direct access to control units, thereby maintaining measurement precision while avoiding manufacturer restrictions and additional costs associated with control unit access.
Solution Approach 2:
The patent replaces the mechanical/electrical access method (direct control unit connection) with a field-based measurement approach (power consumption monitoring). By substituting the physical access requirement with electromagnetic field measurement through power cables, the system achieves process data analysis without violating control unit access restrictions.
2Manufacturing precision
If manual control unit access is used, then manufacturing precision is maintained, but productivity deteriorates due to considerable effort and time requirements
Solution Approach 1:
The patent implements self-service through automated algorithms that independently analyze power consumption data to identify subprocesses, determine phase limits, and detect deviations. The system performs process analysis without requiring manufacturer intervention or manual control unit access, thereby maintaining manufacturing precision while dramatically improving productivity through automation.
Solution Approach 2:
The patent transforms the analysis approach by changing from direct control unit parameter access to power consumption parameter monitoring. This parameter substitution enables automated analysis algorithms to process data continuously without manual intervention, maintaining analytical precision while accelerating the optimization process.
3Extent of automation
If automated subprocess identification is implemented, then extent of automation is improved, but measurement precision may deteriorate without direct control unit access
Solution Approach 1:
The patent applies segmentation by dividing the automated analysis process into distinct algorithmic steps: data acquisition, subprocess identification through pattern recognition, phase limit determination, and deviation detection. This structured segmentation enables high-level automation while maintaining measurement precision through systematic processing of power consumption data that reflects actual process states.
Data Source
AI summary
A device and method for analyzing a sequential process, the sequential process including at least one repeating subprocess, and the method comprising the following steps: Recording process data of the sequential process over a reference time period; Automatically determining phase limits, based on the recorded process data; Identifying at least one repeating subprocess, the duration of which is limited in time by two adjacent phase limits; Determining at least one reference variable for each identified repeating subprocess from the process data recorded in the time period; Recording process data of the sequential process over a time period following the reference time period, and repeating steps b. and c. for the purpose of detecting the recurrence of an identified subprocess; Comparing the recorded process data of the detected subprocess with the at least one reference variable of the corresponding identified subprocess to establish deviations from a normal operation.